Construction Panels

ABSTRACT

A construction panel. The panel includes an insulating member having a first surface and a second surface and a concrete member having a surface that is in substantial contact with the first surface of the insulating member. The panel also includes a structural member having a first portion and a second portion, wherein the first portion of the structural member extends into at least a portion of the insulating member and at least a portion of the concrete member, and wherein the second portion of the structural member extends beyond the second surface of the insulating member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. ProvisionalApplication Ser. No. 61/187,315 filed Jun. 16, 2009 and entitled“Concrete Construction Panels and Methods for Making Same,” and is acontinuation-in-part application of co-pending application Ser. No.11/361,715 filed Feb. 24, 2006 and entitled “Composite Pre-FormedBuilding Panels,” which claims the benefit of priority of U.S.Provisional Application Ser. Nos. 60/656,596 filed Feb. 25, 2005 and60/664,120 filed Mar. 22, 2005, both entitled “Composite Pre-FormedBuilding Panels,” all of which are herein incorporated by reference intheir entirety.

BACKGROUND

Tilt-up wall panels are often used to construct various types ofstructures, mostly in industrial building construction. Tilt-up wallpanels are usually constructed using a sandwich panel design thatincorporates some type of foam insulation core sandwiched between twoface layers of concrete. The sandwich is held together through the useof steel or plastic connectors. The assembly is formed with a woodenstructure that is attached to the floor of a building. The floor towhich the wooden structure is attached requires protection when the formis filled with concrete. Protection generally is accomplished throughthe use of plastic sheathing or release agents applied to the floor.

Site cast tilt-up wall panel sections are typically cast on a preparedconcrete floor of the building in an exterior finished face downorientation. This limits the amount and type of final finish that can beapplied to an exterior (or interior) wall of a building constructed oftilt-up panels. The casting orientation with one face of the concretepanel being placed on the building floor also restricts and limits thefinishing of one surface of the panel until it is lifted into final theposition. Window frame and door frame installation cannot beaccomplished until a wall section is raised into position. A wallsection prepared in this manner typically has lifting attachmentsembedded in the concrete face for the tilt-up process to beaccomplished. These require patching of the concrete face to hide thelifting attachment points.

Wall sections cast using the above-described method have a tendency toplace the concrete structure of the panel in tension when lifted intoposition, thereby requiring additional reinforcements placed to overcomethe stresses created when erecting the sections. Typical site cast wallsections require a wooden forming structure to be built to shape and torestrain the concrete during the pouring of the concrete wall section.This adds many hours of preparation to the casting of on-site wallsegments and requires knowledge of basic carpentry skills by erectors.

Tilt-up concrete walled structures used in non-industrial applicationsnormally need the added installation of steel studs or furring stripsand insulation to finish, wire and plumb the interior spaces of afinished building. These additional construction cost have eliminatedthis type of construction use in specific types of building occupancy,such as residential, professional, retail and office type buildings. Asdescribed above, in order to provide required insulation in certaintypes of building uses, tilt-up wall sections are often made using asandwich design that is created by placing an insulating foam panelbetween two separate concrete pours. This requires the use of connectorsplaced through the insulating board into the first concrete bed and thenthe pouring of a second bed of concrete to create the sandwich design.This process adds additional steps and expense to the wall section beingformed. There also exists the possibility that the connectors used totie the opposing concrete faces together may fail, thus resulting in thedelamination of one or both of the concrete faces.

It is known to use construction elements made of expanded plastics, forexample expanded polystyrene, in forms of boards or section members ofsuitable shape and size. These members provide thermal and soundinsulation functions and have long been accepted by the buildingindustry.

It is also known that, in order to confer adequate self-supportingproperties to such construction elements, one or more reinforcingsection bars of a suitable shape must be incorporated into the mass ofexpanded plastics.

U.S. Pat. Nos. 5,787,665 and 5,822,940 disclose molded composite wallpanels for building construction that include a regular tetragonal bodyof polymer foam and at least one light metal gauge hollow stud in thebody. The edges of the studs are even with a surface of the polymer foamso drywall can be attached thereto.

U.S. Pat. No. 6,098,367 discloses a constructive system applied tobuildings to form walls by means of modular foldable frames that allowfor the placement of blocks or plates. The frames with the resistantchannels, rods, blocks or plates, better resist strong winds and seismicmovements.

U.S. Pat. No. 6,167,624 discloses a method for producing a polymericfoamed material panel including the steps of providing a polymericfoamed material, cutting the polymeric foamed material until reaching apreconfiguration cut point, cutting subsequently from thepreconfiguration cut point a brace-receiving configuration in thepolymeric foamed material, and sliding a brace member into thebrace-receiving configuration to produce a polymeric foamed materialpanel.

U.S. Pat. No. 6,235,367 discloses a molded construction product, havingone or more walls and an inner core section, including a compositionmatrix having a resin system, a catalytic agent, and filler compoundsfor forming the walls; a foam core system for forming the inner coresection, a curing agent and a drying agent. A structural reinforcementsupport system is provided for reinforcing the structural integrity ofthe composition. A locking system is provided for joining one or more ofthe molded products.

EP 0 459 924 discloses a self-supporting construction element made ofexpanded plastics material, specifically a floor element, which includesa substantially parallelepipedic central body in which a reinforcingsection bar, made of a thin metal sheet shaped as an I-beam, isintegrated during the molding step.

U.S. Pat. No. 5,333,429 discloses a composite panel with a structuralload-bearing wooden framework formed by a substantially parallelepipedbody of expanded synthetic material. The panels have a plurality oflongitudinal channels extending for the whole height of the panel. Aseries of channels uniformly spaced and staggered are open on theadjacent face of the panel and have a T-shaped cross section. In theseopen channels fit T-shaped cross section wooden posts, the stem portionof which emerges out of the open channels and project from the surfaceof the panel.

WO 2002/035020 discloses a composite construction element that includesa body made of expanded plastics material and a slab-shaped coatingelement associated to the body. The slab-shaped coating element includesa plurality of substantially adjoining and substantially U-shapedadjacent sections provided with respective means for mechanicallyclinching the slab-shaped element to the expanded plastics material.

While the construction elements described above have on the one handlight weight, comparative ease of installation and low cost, on theother hand their application in the art and flexibility of use have beenrestrained heretofore by their poor fire-resisting properties and/or thepropensity for mold to grow on finished surfaces attached thereto.

This inadequate resistance to fire is essentially related to the factthat construction elements made of expanded plastics show aninsufficient capability to securely hold outer covering layers, such asthe plaster layers used for the outer surface finish or contain theexpanded polymer body, in flammable molten or liquid form, that occursfrom the heat generated from a fire.

When exposed to fire, in fact, the expanded plastic materials soonshrink into a shapeless mass of reduced volume, which can flow and burn,and in some cases with the ensuing separation of the outer coveringlayers and rapid collapse of the whole structure.

In addition, an undesirable separation of the outer covering layers maybe caused in some instances by a premature “aging” of the plasticssurface to which these coverings adhere, a separation which may befurther fostered by exposure to heat sources, dusts, fumes, vapors, orchemical substances coming from a source close to the constructionelements.

U.S. Pat. No. 6,298,622 and WO 2004/101905 disclose an approach toovercoming the above-described problem by using a self-supportingconstruction element of expanded plastics for use as floor elements andwalls of buildings. The construction elements include a central body,substantially parallelepipedic in shape and having two opposite faces;at least one reinforcing section bar transversally extending across thecentral body between the faces thereof and embedded in the expandedplastics; a lath for supporting at least one layer of a suitablecovering material, associated to a fin of the reinforcing section barlying flush with and substantially parallel to at least one of the facesof the construction element. However, moisture buildup between the lathand construction element can lead to mold and mildew growth and theability to easily run electrical lines without cutting into theconstruction elements have limited the desirability of this approach.

SUMMARY

In various embodiments, the present invention is directed to methods ofconstructing an elevated stay in place, face cast, tilt-up, concretecasting bed used for creating tilt-up wall sections. Such tilt-up wallsections may be pre-studded and insulated for interior finishes. Apre-formed casting bed may form part of the concrete tilt-up wallsection and remain attached to the wall after casting and during thelifting phase of construction. The casting bed may then provide an areafor utilities to run, finishing materials to be attached, insulation ofthe finished wall, etc. In one embodiment, the casting bed comprisesmolded expandable polystyrene (EPS) containing embedded and exposedlight gauge steel structural and nonstructural members to which concretescreeding, reinforcement guides, forming assemblies, etc. may beattached.

Various embodiments of the present invention are directed to aconstruction panel. The panel includes an insulating member having afirst surface and a second surface and a concrete member having asurface that is in substantial contact with the first surface of theinsulating member. The panel also includes a structural member having afirst portion and a second portion, wherein the first portion of thestructural member extends into at least a portion of the insulatingmember and at least a portion of the concrete member, and wherein thesecond portion of the structural member extends beyond the secondsurface of the insulating member

Those and other details, objects, and advantages of the presentinvention will become better understood or apparent from the followingdescription and drawings showing embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 2 is a cross-sectional view of a pre-formed building panel adaptedfor use with stucco according to various embodiments of the presentinvention;

FIG. 3 is a side elevational view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 4 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 5 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 6 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 7 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 8 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 9 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 10 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 11 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 12 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 13 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 14 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 15 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 16 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 17 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 18 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 19 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 20 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 21 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 22 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 23 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 24 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 25 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 26 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 27 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 28 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 29 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 30 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 31 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 32 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 33 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 34 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 35 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 36 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 37 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 38 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 39 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 40 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 41 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 42 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 43 is a side elevational view of a stud according to variousembodiments of the present invention;

FIG. 44 is a perspective view of the building panel of FIG. 41;

FIG. 45 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 46 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 47 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 48 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 49 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 50 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 51 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 52 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 53 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 54 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 55 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 56 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 57 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 58 is a perspective view of a stud according to various embodimentsof the present invention;

FIG. 59 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 60 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 61 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 62 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 63 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 64 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 65 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 66 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 67 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 68 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 69 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 70 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 71 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 72 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 73 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 74 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 75 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 76 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 77 is a cross-sectional view of a stud according to variousembodiments of the present invention;

FIG. 78 is a side elevational view of a portion of a stud according tovarious embodiments of the present invention;

FIG. 79 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 80 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 81 is a cross-sectional view of a portion of a pre-formed buildingpanel according to various embodiments of the present invention;

FIG. 82 is a cross-sectional view of a portion of a pre-formed buildingpanel according to various embodiments of the present invention;

FIG. 83A is a cross-sectional view of a portion of a pre-formed buildingpanel according to various embodiments of the present invention;

FIG. 83B is a cross-sectional view of a portion of a pre-formed buildingpanel according to various embodiments of the present invention;

FIG. 83C is a cross-sectional view of a portion of a pre-formed buildingpanel according to various embodiments of the present invention;

FIG. 84 is a cross-sectional view of pre-formed building panelsconnected using a gasket according to various embodiments of the presentinvention;

FIG. 85 is a cross-sectional view of pre-formed building panelsconnected using a gasket according to various embodiments of the presentinvention;

FIG. 86 is a cross-sectional view of pre-formed building panelsconnected using a gasket according to various embodiments of the presentinvention;

FIG. 87 is a cross-sectional view of pre-formed building panelsconnected using a gasket according to various embodiments of the presentinvention;

FIG. 88 is a rear elevational view of a wall system according to variousembodiments of the present invention;

FIG. 89 is a front elevational view of a wall system according tovarious embodiments of the present invention;

FIG. 90 is a rear perspective view of a wall system according to variousembodiments of the present invention;

FIG. 91 is a rear view of a portion of a wall system showing spacer barsaccording to various embodiments of the present invention;

FIG. 92 is a partial top perspective view of a molding attached to apre-formed building panel according to various embodiments of thepresent invention;

FIG. 93 is a cross-sectional view of the molding of FIG. 92;

FIG. 94 is a perspective view of an interior corner post according tovarious embodiments of the present invention;

FIG. 95 is a side elevational view of an interior corner post accordingto various embodiments of the present invention;

FIG. 96 is a cross-sectional view of an interior corner post accordingto various embodiments of the present invention;

FIG. 97 is a cross-sectional view of a stud for the interior cornerassembly of various embodiments of the present invention;

FIG. 98 is an interior corner assembly of various embodiments of thepresent invention;

FIG. 99 is a cross-sectional view of building panels connected by aninterior corner assembly according to various embodiments of the presentinvention;

FIG. 100 is a perspective view of an exterior corner post according tovarious embodiments of the present invention;

FIG. 101 is a side elevational view of an exterior corner post accordingto various embodiments of the present invention;

FIG. 102 is a cross-sectional view of an exterior corner post accordingto various embodiments of the present invention;

FIG. 103 is a cross-sectional view of a stud for an outer cornerassembly of various embodiments of the present invention;

FIG. 104 is a cross-sectional view of a stud for an exterior cornerassembly of various embodiments of the present invention;

FIG. 105 is an exterior corner assembly of various embodiments of thepresent invention;

FIG. 106 is a cross-sectional view of building panels connected by anexterior corner assembly according to various embodiments of the presentinvention;

FIG. 107 is a side elevational view of a portion of a stud and spacerbar assembly according to various embodiments of the present invention;

FIG. 108 is a cross-sectional view of a stud and spacer bar assemblyaccording to various embodiments of the present invention;

FIG. 109 is a perspective view of a wall system according to variousembodiments of the present invention;

FIG. 110 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 111 is a cross-sectional view of a pre-formed building panelaccording to various embodiments of the present invention;

FIG. 112 is a perspective view of a construction method according tovarious embodiments of the present invention;

FIG. 113 is a partial perspective view of a level track according tovarious embodiments of the present invention;

FIG. 114 is a side elevational view of a pre-formed building panel andfloor connector system according to various embodiments of the presentinvention;

FIG. 115 is a side elevational view of a pre-formed building panel andfloor connector system according to various embodiments of the presentinvention;

FIG. 116 is a cross-sectional view of a concrete composite pre-formedbuilding panel system according to various embodiments of the presentinvention;

FIG. 117 is a cross-sectional view of a concrete composite pre-formedbuilding panel system according to various embodiments of the presentinvention;

FIG. 118 is a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to various embodiments of the presentinvention;

FIG. 119 is a cross-sectional view of a reinforced body for use inmaking the concrete composite pre-formed tilt-up insulated panel in FIG.118;

FIG. 120 is a perspective view of an embedded metal member for use inmaking the reinforced body in FIG. 119 and the concrete compositepre-formed tilt-up insulated panels in FIGS. 118 and 121;

FIG. 121 is a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to various embodiments of the presentinvention;

FIG. 122 is a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to various embodiments of the presentinvention;

FIG. 123 is a cross-sectional view of a reinforced body for use inmaking the concrete composite pre-formed tilt-up insulated panel in FIG.122;

FIG. 124 is a perspective view of an embedded metal member for use inmaking the reinforced body in FIG. 123 and the concrete compositepre-formed tilt-up insulated panels in FIGS. 122 and 125;

FIG. 125 is a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to various embodiments of the presentinvention;

FIG. 126A is a perspective view of a floor system according to variousembodiments of the present invention;

FIG. 126B is a perspective view of a floor system according to variousembodiments of the present invention;

FIG. 127 is a cross-sectional view of metal members that can be used inthe pre-formed building panels according to various embodiments of thepresent invention;

FIG. 128 is a cross-sectional view of metal members that can be used inthe pre-formed building panels according to various embodiments of thepresent invention;

FIG. 129 is a cross-sectional view of metal members that can be used inthe pre-formed building panels according to various embodiments of thepresent invention; and

FIG. 130 illustrates a manufacturer/customer method of designing customcomposite building panels according to various embodiments of thepresent invention;

FIG. 131 is a cross-sectional view of a wind load resistance testapparatus for testing panels according to various embodiments of thepresent invention;

FIG. 132 is a perspective view of the wind load resistance testapparatus for testing panels according to various embodiments of thepresent invention;

FIG. 133 is a top plan view of the test apparatus of FIG. 132;

FIG. 134 is a side elevational view of the test apparatus of FIG. 132;

FIG. 135 is a cross-sectional view of the test apparatus of FIG. 132 forscenario #2;

FIG. 136 is a top plan view of a simulated building panel assemblyaccording to various embodiments of the present invention;

FIG. 137 is a top plan view of a simulated building panel assemblyaccording to various embodiments the present invention;

FIG. 138 is a top plan view of a simulated building panel assemblyaccording to various embodiments of the present invention;

FIG. 139 is a top plan view of a simulated building panel assemblyaccording to various embodiments of the present invention;

FIG. 140 is a top plan view of a simulated building panel assemblyaccording to various embodiments of the present invention;

FIG. 141 illustrates a top perspective view of an embodiment of a wallpanel prior to addition of concrete;

FIG. 142 illustrates a top perspective view of an embodiment of the wallpanel of FIG. 141 after a concrete form and concrete reinforcement areadded;

FIG. 143 illustrates a top perspective view of an embodiment of the wallpanel of FIG. 141 during the addition of concrete;

FIG. 144 illustrates an exterior view of an embodiment of the wall panelof FIG. 141 as it is being lifted into place;

FIG. 145 illustrates an interior view of an embodiment of the wall panelof FIG. 141 as it is being lifted into place; and

FIG. 146 illustrates a cross-sectional view of an embodiment of the wallpanel of FIG. 141.

DETAILED DESCRIPTION

For the purpose of the description hereinafter, the terms “upper,”“lower,” “inner”, “outer”, “right,” “left,” “vertical,” “horizontal,”“top,” “bottom,” and derivatives thereof, shall relate to the inventionas oriented in the drawing Figures. However, it is to be understood thatthe invention may assume alternate variations and step sequences exceptwhere expressly specified to the contrary. It is also to be understoodthat the specific devices and processes, illustrated in the attacheddrawings and described in the following specification, is an exemplaryembodiment of the present invention. Hence, specific dimensions andother physical characteristics related to the embodiment disclosedherein are not to be considered as limiting the invention. In describingthe embodiments of the present invention, reference will be made hereinto the drawings in which like numerals refer to like features of theinvention.

Other than where otherwise indicated, all numbers or expressionsreferring to quantities, distances, or measurements, etc. used in thespecification and claims are to be understood as modified in allinstances by the term “about.” Accordingly, unless indicated to thecontrary, the numerical parameters set forth in the followingspecification and attached claims are approximations that can varydepending upon the desired properties, which the present inventiondesires to obtain. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical values, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective measurement methods.

Also, it should be understood that any numerical range recited herein isintended to include all sub-ranges subsumed therein. For example, arange of “1 to 10” is intended to include all sub-ranges between andincluding the recited minimum value of 1 and the recited maximum valueof 10; that is, having a minimum value equal to or greater than 1 and amaximum value of equal to or less than 10. Because the disclosednumerical ranges are continuous, they include every value between theminimum and maximum values. Unless expressly indicated otherwise, thevarious numerical ranges specified in this application areapproximations.

Various embodiments of the present invention provide pre-formed buildingpanels that comprise one or more reinforcing structural elements ormembers running longitudinally, which may be partially exposed, with theremainder of the reinforcing structural element(s) partiallyencapsulated in an expanded polymer matrix, which acts as a thermalbreak. The reinforcing structural elements can be flanged lengthwise oneither side to provide attachment points for external objects to thepanel. Perforations in the reinforcing structural elements which areencapsulated in the expanded polymer matrix allow for fusionperpendicularly. Perforations in the exposed portion of the reinforcingstructural element provide attachment points for lateral bracing andutility installation. In some embodiments, a tongue and grooveconnection point design provides for panel abutment, weep holes providefor the draining of moisture or the venting of vapors and attachmentpoints for external objects. In some embodiments, recessed areas onopposing panel ends provide an area of member to member connection with“C” channels running along the top and bottom of the structural member.In some embodiments, longitudinal holes can be provided through theexpanded polymer matrix to provide areas or channels for the placementof utilities and/or the venting of gasses. Such construction also servesto reduce the overall weight of the panels. The longitudinal holes canbe variable in diameter and location. Panel manufacture can beaccomplished through the use of a semi-continuous or continuous moldingprocess allowing for variable panel lengths.

The composite building panels of the present invention will now bediscussed in terms of embodiments providing wall units and wall systems.However, one skilled in the art would understand that the compositebuilding panels of the present invention can be used for a variety ofuses, for example flooring units, ceiling units, etc., such as will bediscussed in detail below. Therefore, the following discussion regardingwall units and wall systems is not intended to limit the scope of thepresent invention.

As shown in FIG. 1, composite building panel or wall unit 10 accordingto the present invention comprises a central body 9 comprised of anexpanded polymer matrix (expanded polymer body 12).

As used herein, the term “expandable polymer matrix” refers to apolymeric material in particulate or bead form that can be impregnatedwith a blowing agent such that when the particulates and/or beads areplaced in a mold and heat is applied thereto, evaporation of the blowingagent (as described below) effects the formation of a cellular structureand/or an expanding cellular structure in the particulates and/or beadsand the outer surfaces of the particulates and/or beads fuse together toform a continuous mass of polymeric material conforming to the shape ofthe mold.

As used herein, the term “polymer” is meant to encompass, withoutlimitation, homopolymers, copolymers and graft copolymers.

The expanded polymer matrix makes up the expanded polymer body, panelsand/or forms described herein below. The expanded polymer matrix istypically molded from expandable thermoplastic particles. Theseexpandable thermoplastic particles are made from any suitablethermoplastic homopolymer or copolymer. Particularly suitable for useare homopolymers derived from vinyl aromatic monomers including styrene,isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes,chlorostyrene, tert-butylstyrene, and the like, as well as copolymersprepared by the copolymerization of at least one vinyl aromatic monomeras described above with one or more other monomers, non-limitingexamples being divinylbenzene, conjugated dienes (non-limiting examplesbeing butadiene, isoprene, 1,3- and 2,4-hexadiene), alkyl methacrylates,alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinylaromatic monomer is present in at least 50% by weight of the copolymer.In an embodiment of the invention, styrenic polymers are used,particularly polystyrene. However, other suitable polymers can be used,such as polyolefins (e.g. polyethylene, polypropylene), polycarbonates,polyphenylene oxides, and mixtures thereof.

As used herein, the terms “(meth)acrylic” and “(meth)acrylate” are meantto include both acrylic and methacrylic acid derivatives, such as thecorresponding alkyl esters often referred to as acrylates and(meth)acrylates, which the term “(meth)acrylate” is meant to encompass.

In various embodiments of the invention, the expandable thermoplasticparticles are expandable polystyrene (EPS) particles. These particlescan be in the form of beads, granules, or other particles convenient forthe expansion and molding operations. Particles polymerized in anaqueous suspension process are essentially spherical and are useful formolding the expanded polymer body, panels and/or forms described hereinbelow. These particles can be screened so that their size ranges fromabout 0.008 to about 0.15 inch (0.20 mm to about 3.81 mm) prior toexpansion.

The expandable thermoplastic particles can be impregnated using anyconventional method with a suitable blowing agent. As a non-limitingexample, the impregnation can be achieved by adding the blowing agent tothe aqueous suspension during the polymerization of the polymer, oralternatively by re-suspending the polymer particles in an aqueousmedium and then incorporating the blowing agent as taught in U.S. Pat.No. 2,983,692. Any gaseous material or material which will produce gaseson heating can be used as the blowing agent. Conventional blowing agentsinclude aliphatic hydrocarbons containing 4 to 6 carbon atoms in themolecule, such as butanes, pentanes, hexanes, and the halogenatedhydrocarbons, e.g. CFC's and HCFC's, which boil at a temperature belowthe softening point of the polymer chosen. Mixtures of these aliphatichydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbonsblowing agents or water can be used as the sole blowing agent as taughtin U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents,water-retaining agents are used. The weight percentage of water for useas the blowing agent can range from 1 to 20%. The texts of U.S. Pat.Nos. 6,127,439; 6,160,027; and 6,242,540 are incorporated herein byreference.

The impregnated thermoplastic particles are generally pre-expanded to adensity of at least 0.1 lb/ft³, in some cases at least 0.25 lb/ft³, inother cases at least 0.5 lb/ft³, in some situations at least 0.75lb/ft³, in other situations at least 1 lb/ft³, and in some instances atleast about 2 lb/ft³. Also, the density of the impregnated pre-expandedparticles can be up to 12 lb/ft³, in some cases up to 10 lb/ft³, and inother cases up to 5 lb/ft³. The density of the impregnated pre-expandedparticles can be any value or range between any of the values recitedabove. The pre-expansion step is conventionally carried out by heatingthe impregnated beads via any conventional heating medium, such assteam, hot air, hot water, or radiant heat. One generally acceptedmethod for accomplishing the pre-expansion of impregnated thermoplasticparticles is taught in U.S. Pat. No. 3,023,175.

The impregnated thermoplastic particles can be foamed cellular polymerparticles as taught in U.S. Patent Publication No. 2002/0117769, theteachings of which are incorporated herein by reference. The foamedcellular particles can be polystyrene that are pre-expanded and containa volatile blowing agent at a level of less than 6.0 weight percent, insome cases ranging from about 2.0 wt % to about 5.0 wt %, and in othercases ranging from about 2.5 wt % to about 3.5 wt % based on the weightof the polymer.

An interpolymer of a polyolefin and in situ polymerized vinyl aromaticmonomers that can be included in the expandable thermoplastic resinaccording to various embodiments of the present invention is disclosedin U.S. Pat. Nos. 4,303,756 and 4,303,757 and U.S. ApplicationPublication No. 2004/0152795, the relevant portions of which are hereinincorporated by reference. Non-limiting examples of interpolymers thatcan be used in the present invention include those available under thetrade name ARCEL®, available from NOVA Chemicals Inc., Pittsburgh, Pa.and PIOCELAN®, available from Sekisui Plastics Co., Ltd., Tokyo, Japan.

The expanded polymer matrix can include customary ingredients andadditives, such as pigments, dyes, colorants, plasticizers, mold releaseagents, stabilizers, ultraviolet light absorbers, mold preventionagents, antioxidants, and so on. Typical pigments include, withoutlimitation, inorganic pigments such as carbon black, graphite,expandable graphite, zinc oxide, titanium dioxide, and iron oxide, aswell as organic pigments such as quinacridone reds and violets andcopper phthalocyanine blues and greens.

In one embodiment of the invention the pigment is carbon black, anon-limiting example of such a material is EPS SILVER® pigment,available from NOVA Chemicals Inc.

In another embodiment of the invention the pigment is graphite, anon-limiting example of such a material is NEOPOR® pigment, availablefrom BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein, Germany.

When materials such as carbon black and/or graphite are included in thepolymer particles, improved insulating properties, as exemplified byhigher R values for materials containing carbon black or graphite (asdetermined using ASTM-C578), are provided. As such, the R value of theexpanded polymer particles containing carbon black and/or graphite ormaterials made from such polymer particles are at least 5% higher thanobserved for particles or resulting articles that do not contain carbonblack and/or graphite.

The pre-expanded particles or “pre-puff” are heated in a closed mold inthe semi-continuous or continuous molding process described below toform the pre-formed building panels according to various embodiments ofthe present invention.

In some embodiments, portions of the central body 9 can further comprisematerials in addition to the expanded polymer matrix, as nonlimitingexamples ultraviolet (UV) stabilizers, heat stabilizers, flameretardants, structural enhancements, biocides, and combinations thereof.

Generally, the central body 9 is substantially parallelepipedic inshape, i.e., a polyhedron having six parallelogram faces that areparallel to the opposite face. As shown in FIG. 1, the central body 9comprises opposite faces, including a first surface or inner surface 30and an opposing second surface or outer surface 24, a first end 17 and asecond end 19, discussed in detail below.

In some embodiments of the invention, outer surface 24 of expandedpolymer body 12 can have any desirable type of surface. In someinstances, outer surface 24 will be smooth, in other instances groovescan be cut into or molded into outer surface 24 to facilitate theapplication of finishing surfaces and surface finishing materials suchas stucco and the like. In order to facilitate the application of stuccoto outer surface 24, T-slots 1300 can be cut into or molded into outersurface 24. Any suitable type of stucco can be used, such as naturalmaterial stucco or polymer based stucco. Thus, by including T-slots 1300in outer surface 24, a stucco ready wall panel surface is provided. Moreparticularly, T-slots 13 provide a mechanical connection for stuccoadhesion and no secondary mesh is required. In a particular embodimentof the invention, T-slots 1300 allow for the use of natural materialstucco as this type of stucco is able to breathe and not trap water.When stucco is not applied to outer surface 24, T-slots 1300 can be usedas water condensation channels for other finishing techniques.

Referring now to FIG. 1, expanded polymer body 12 has a width 32. Theexpanded polymer body 12 can be manufactured in a variety of differentsizes that would facilitate its safe handling and minimal damage duringshipping and installation thereof. The width 32 of expanded polymer body12 may be at least 3.28 feet (1 m), in some cases at least 4.92 feet(1.5 m), and in other cases at least 6.56 feet (2 m) and can be up to82.02 feet (25 m), in some cases up to 65.62 feet (20 m), in other casesup to 49.21 feet (15 m), in some instances up to 32.81 feet (10 m) andin other instances up to 16.40 feet (5 m). The width 32 of expandedpolymer body 12 can be any value or can range between any of the valuesrecited above.

The height 33 of expanded polymer body 12 can be any height that allowsfor the safe handling and minimal damage to expanded polymer body 12during shipping and installation. See FIG. 3. In various embodiments,the height 33 of expanded polymer body 12 is generally determined by thelength of embedded metal studs 14 and 16. See also FIG. 1. In variousembodiments, the height 33 of expanded polymer body 12 can be at least3.28 feet (1 m) and in some cases at least 4.92 feet (1.5 m) and can beup to 9.84 feet (3 m) and in some cases up to 8.20 feet (2.5 m). Theheight 33 of expanded polymer body 12 can be any value or can rangebetween any of the values recited above.

Referring now to FIG. 1, expanded polymer body 12 can have a thickness15, measured as the distance from inner surface 30 to outer surface 24,of at least 0.79 inches (2 cm), in some cases at least one inch (2.5cm), and in other cases at least 1.18 inches (3 cm) and can be up to3.94 inches (10 cm), in some cases up to 3.15 inches (8 cm), and inother cases up to 2.36 inches (6 cm) from inner surface 30 of expandedpolymer body 12. One skilled in the art will appreciate that the polymerbody 12 could be provided in other thicknesses without departing fromthe spirit and scope of the present invention.

In some embodiments, expanded polymer body 12 can comprise one or moreopenings 18 that traverse all or part of the length and/or width ofexpanded polymer body 12, for example holes, conduits or chases can bemolded into and extend along the length of the expanded polymer body 12.It is conceivable, however, that the expanded polymer body 12 may alsobe provided without any such openings therethrough. In some embodimentsof the present invention, the holes, conduits or chases may be used asaccess ways for accommodating utilities, such as wiring, plumbing andexhaust vents within the walls, ceilings, floors and roofs constructedaccording to various embodiments of the present invention.

Openings 18 can have various cross-sectional shapes, non-limitingexamples being round, oval, elliptical, square, rectangular, triangular,hexagonal or octagonal. The cross-sectional size or area of openings 18can be uniform or they can vary independently of each other with regardto size and location relative to inner surface 30 and outer surface 24.The spacing between each opening 18 can be at least 1.97 inches (5 cm)and in some cases at least 3.94 inches (10 cm) and can be up to 3.61feet (110 cm), in some cases up to 3.28 ft (100 cm), in other cases upto 2.46 ft (75 cm), and in some instances up to 1.97 ft (60 cm) measuredfrom a midpoint of one opening 18 to a midpoint of an adjacent opening18. The spacing between openings 18 can independently be any distance orrange between any of the distances recited above.

The cross-sectional area of openings 18 can also vary independently onefrom another or they can be uniform. The cross-sectional area ofopenings 18 is limited by the dimensions of expanded polymer body 12, asopenings 18 will fit within the dimensions of expanded polymer body 18.The cross-sectional area of openings 18 can independently be at least0.155 in² (1 cm²), in some cases at least 0.775 in² (5 cm²), and inother cases at least 1.395 in² (9 cm²) and can be up to 20.15 in² (130cm2), in some cases up to 15.50 in² (100 cm²), in other cases up to11.625 in2 (75 cm²). The cross-sectional area of openings 18 canindependently be any value or range between any of the values recitedabove.

Referring now to FIG. 4, in other embodiments of the invention, the wallunits, floor units and expanded polymer panels or central body have afirst end 17, such as a male “tongue” end or edge, and a second end 19,such as for example a female “groove” end or edge, that facilitates a“tongue and groove” union of two matching wall units, floor units andexpanded polymer panels. The tongue and groove union can be non-linearand can provide for a weep hole and/or larger opening to accommodateplumbing lines. Typically the tongue and groove union provides a flatsurface at the union to allow for easy application of sealing tape toseal the union or joint if desired.

Various embodiments of the present invention further include reinforcingmembers to provide strength and rigidity to the panel and to generallyenhance the panel's structural integrity to thereby enable the panel towithstand the anticipated loads and stresses that it will likelyencounter when installed. The reinforcing members employed in variousembodiments of the present invention may comprise a variety of differentstructural members, bars, joists, studs and other structural profileswithout departing from the spirit and scope of the present invention.FIG. 1 illustrates the use of reinforcing members in the form ofconventional metal studs 14 and 16. As can be seen in that Figure, themetal studs 14 and 16 are spaced from each other across the width 32 ofthe central body 9 and extend longitudinally therein as illustrated inFIG. 3. As shown in FIG. 1, in one embodiment wall unit 10 comprises aleft facing embedded metal stud 14, and right facing embedded metal stud16. One skilled in the art would understand that in alternativeembodiments a single reinforcing member or more than two reinforcingmembers can be used as desired.

The reinforcing members used in various embodiments of the invention canbe made of any suitable material. Suitable materials are those that addstrength, stability and structural integrity to the pre-formed buildingpanels. Such materials provide embedded framing studs meeting therequirements of applicable test methods known in the art, asnon-limiting examples ASTM A 36/A 36M-05, ASTM A 1011/A 1011M-05a, ASTMA 1008/A 1008M-05b, and ASTM A 1003/A 1003M-05 for various types ofsteel.

Suitable materials include, but are not limited to metals, constructiongrade plastics, composite materials, ceramics, combinations thereof, andthe like. Suitable metals include, but are not limited to, aluminum,steel, stainless steel, tungsten, molybdenum, iron and alloys andcombinations of such metals. In various particular embodiments of theinvention, the reinforcing members are made of a light gauge metal.

Suitable construction grade plastics include, but are not limited toreinforced thermoplastics, thermoset resins, and reinforced thermosetresins. Thermoplastics include polymers and polymer foams made up ofmaterials that can be repeatedly softened by heating and hardened againon cooling. Suitable thermoplastic polymers include, but are not limitedto homopolymers and copolymers of styrene, homopolymers and copolymersof C₂ to C₂₀ olefins, C₄ to C₂₀ dienes, polyesters, polyamides,homopolymers and copolymers of C₂ to C₂₀ (meth)acrylate esters,polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides,polyurethanes, and combinations thereof.

Suitable thermoset resins are resins that when heated to their curepoint, undergo a chemical cross-linking reaction causing them tosolidify and hold their shape rigidly, even at elevated temperatures.Suitable thermoset resins include, but are not limited to alkyd resins,epoxy resins, diallyl phthalate resins, melamine resins, phenolicresins, polyester resins, urethane resins, and urea, which can becrosslinked by reaction, as non-limiting examples, with diols, triols,polyols, and/or formaldehyde.

Reinforcing materials that can be incorporated into the thermoplasticsand/or thermoset resins include, but are not limited to carbon fibers,aramid fibers, glass fibers, metal fibers, fiberglass, carbon black,graphite, clays, calcium carbonate, titanium dioxide, woven fabric orstructures of the above-referenced fibers, and combinations thereof.

A non-limiting example of construction grade plastics are thermosettingpolyester or vinyl ester resin systems reinforced with fiberglass thatmeet the requirements of required test methods known in the art,non-limiting examples being ASTM D790, ASTM D695, ASTM D3039 and ASTMD638.

The thermoplastics and thermoset resins can optionally include otheradditives, as a non-limiting example ultraviolet (UV) stabilizers, heatstabilizers, flame retardants, structural enhancements, biocides, andcombinations thereof.

In an embodiment of the invention, one or more surfaces of thereinforcing members used herein can have a texturized surface. As usedherein, “texturized surface” refers to a non-smooth surface thatincludes surface alterations, non-limiting examples of such includedimples and corrugation. Methods for texturizing such surfaces aredisclosed, for example in U.S. Pat. Nos. 6,183,879 and 5,689,990, thedisclosures of which are herein incorporated by reference in theirentirety. Texturized surfaces can provide improved strength in thereinforcing members and/or improved adherence between the reinforcingmembers and the expanded polymer matrix and other materials,non-limiting examples of which include concrete, stucco, cement andmortar.

The reinforcing members can have a variety of different thicknessesdepending upon the intended use and desired physical properties of thepanel. For example, in various embodiments, the reinforcing members mayhave a thickness 41 of at least 0.016 in (0.4 mm) to up to 0.394 in (10mm), in some instances at least 0.039 in (1 mm) and in other instancesat least up to 0.314 in (8 mm). As indicated above, the reinforcingmembers that may be employed in various embodiments of the presentinvention and may have a variety of different cross-sectional shapes.For example, such reinforcing members may comprise studs referred to asC-type studs, CT-type studs, and CC-type studs. It is also conceivablethat reinforcing members with other cross-sectional shapes andthicknesses could be employed. In the embodiments depicted in FIGS. 1,4, and 6, C-type studs are employed.

Referring now to FIG. 1, there is shown a cross-sectional view of apreformed building panel 10 that has an expanded polymer body 12 thatincludes reinforcing members in the form of metal studs 14 and 16 thatare partially embedded therein. The embedded metal studs 14 and 16 haveembedded side portions 20 and 22, at least a portion of which isembedded in the expanded polymer matrix. The portion of the framing studembedded in the expanded polymer matrix is referred to as the thermalportion of the stud. The portion of the embedded framing stud that isnot embedded in the polymer matrix is referred to as the structuralportion of the stud.

In some embodiments, such as the embodiment depicted in FIG. 1, theembedded side portions 20 and 22 do not extend all the way through theexpanded polymer body 12 to touch the outer surface 24 of expandedpolymer body 12. Embedded side portions 20 and 22 can extend from innersurface 30 any distance into the expanded polymer body 12 to the outersurface 24.

Referring now to FIG. 4, in some embodiments, the embedded side portions20 and 22 extend all the way through the expanded polymer body 12 to beflush with the outer surface 24 of expanded polymer body 12 or, as shownin FIG. 137, emerge through the outer surface 24 to provide exposedportion 35. Exposed portion 35 of embedded side portions 20 and 22 canfacilitate attachment of finish surfaces and materials thereto.

Embedded side portions may extend at least 0.39 inches (1 cm), in somecases at least 0.79 inches (2 cm), and in other cases at least 1.18inches (3 cm) into expanded polymer body 12 away from inner surface 30.Also, embedded side portions 20 and 22 can extend up to 3.94 inches (10cm), in some cases up to 3.15 inches (8 cm), and in other cases up to2.36 inches (6 cm) away from inner surface 30 into expanded polymer body12. One skilled in the art will appreciate that the embedded sideportions 20 and 22 can be located within the expanded polymer body 12 ata variety of different distances from the inner surface 30 or can rangebetween any of the distances recited above from the inner surface 30into the polymer body 12.

For example, in still other embodiments of the present invention,embedded side portions 20 and 22 can be embedded within the polymer body12 at distances of about from 1/10 to 9/10, in some cases ⅓ to ⅔ and inother cases ¼ to ¾ of the thickness of expanded polymer body 12 from theinner surface 30. However, in other embodiments, side portions 20 and 22may be completely exposed to facilitate attachment of finish surfaces ormembers thereto.

In some embodiments of the present invention, embedded metal studs 14and 16 have a cross-sectional shape that includes embedding lengths 34and 36, embedded side portions 20 and 22 and exposed side portions 26and 28. The orientation of embedded metal studs 14 and 16 is referencedby the direction of open ends 38 and 40. In an embodiment of theinvention shown in FIG. 1, open ends 38 and 40 are oriented away fromeach other. In this embodiment, wall unit 10 has greater rigidity and iseasier to handle without bending. In other embodiments of the inventionshown in FIG. 41, open ends 38 and 40 may also be oriented facing in thesame direction.

Referring now to FIGS. 1 and 4, each exposed side portion 26, 28comprises a web or web 1012, 1014. In some embodiments, each exposedside portion 26, 28 can further comprise a flange 1016, 1018 extendinggenerally perpendicularly from the web 1012, 1014. In some embodiments,each exposed side portion 26, 28 can further comprise a lip portion1020, 1022 extending generally perpendicularly from the flange 1004,1006.

Referring to FIGS. 6 and 7, there is shown a C-type stud denotedgenerally as 1500. As shown in FIG. 7, the stud 1500 has a body 1502that has a length 1501 and a width 1503. The stud 1500 also has athickness 41 as illustrated in FIG. 6. The length 1501, width 1503, andthickness 41 may vary depending upon the application and the anticipatedloading conditions that the panel must withstand. For example, invarious embodiments, the length 1501 of the body 1502 may be about 3.28feet (1 m) to 9.84 feet (3 m), for example eight feet (2.44 m). Thewidth 1503 of body 1502 may be about 3.94 inches (10 cm) to about 7.87inches (20 cm), for example, about 6 inches (15.24 cm). It isconceivable, however, that other lengths 1501 and widths 1503 may beemployed. In various embodiments, the body 1502 comprises a first sideportion 1504 and an opposed second side portion 1506. The first sideportion 1504 and the second side portion 1506 are positioned along alaterally extending axis 1507 extending across the width of the body1502. The first side portion 1504 of the body 1502 comprises a firstportion 1509 of a web 1508 having an end 1510, a flange 1512 extendinggenerally perpendicularly from the end 1510 of the web 1508 and,optionally, a return lip 1514 extending generally perpendicularly fromthe flange 1512 and in a direction generally away from the end 1510 ofthe web 1508 making up at least a part if the thermal portion of thestud.

The second side portion 1506 of the body 1502 comprises a second portion1511 (shown in FIG. 5) of the web 1508 having an end 1516 opposite end1510, a flange 1518 extending generally perpendicularly from the end1516 of the web 1508 and, optionally, a return lip 1520 extendinggenerally perpendicularly from the flange 1518 and in the direction offlange 1512. The portion of the embedded framing stud that is notembedded in the polymer matrix is referred to as the structural portionof the stud.

Referring now to FIGS. 15, 16, 17, 20, 24, 28 and 32, a CT-type stud,denoted generally as 1522, comprises a body 1524 having a length 1523, awidth 1525 and a thickness 41. Values of the length 1523 and width 1525of the CT-stud 1522 may be similar to those of the C-stud 1500 discussedabove or other lengths and/or thicknesses may be employed.

As shown in FIG. 16, the body 1524 comprises a first side portion 1526and an opposed second side portion 1528. The first side portion 1526 andthe second side portion 1528 are positioned along a laterally extendingaxis 1529 traversing the width of the body 1524. The first side portion1526 comprises a first portion 1531 of the first web 1530 (the thermalportion) having a first end 1532, a first flange 1536 extendinggenerally perpendicularly from the first end 1532 of the first web 1530,a second web 1538 having a first end 1540 and a second end 1542extending generally perpendicularly from the first flange 1536 andpositioned generally parallel to the first web 1530 and a second flange1544 having a first end 1546, second end 1548 and a central portion 1550extending therebetween. The central portion 1550 of the second flange1544 is positioned generally perpendicularly to the first end 1540 ofthe second web 1538. Generally, the second flange 1544 is positioned toform a T-shape with respect to the second web portion 1538.

The second side portion 1528 of the body comprises a second portion 1533(the structural portion—shown in FIG. 15) of the first web 1530 having asecond end 1534, a third flange 1552 extending generally perpendicularlyfrom the second end 1534 of the first web 1530, and, optionally, areturn lip 1554 extending generally perpendicularly from the thirdflange 1552 (see FIG. 16).

Some of the differences between the different embodiments of CT-typestuds 1522 are based on the position of the CT-type stud 1522 relativeto the expanded polymer body 12, the length of the first web 1530 andthe length of the second web 1538.

As a non-limiting example, in the embodiment illustrated in FIG. 15, thefirst portion 1531 of the first side portion 1526 is embedded in theexpanded polymer body 12 with the second flange 1544 and a portion 1539of the second web 1538 extending beyond the outer surface 24 of theexpanded polymer body 12. The length of the first web 1530 may be about5.12 inches (13 cm) to about 5.90 inches (15 cm), for example 5.51inches (14 cm). Further, the length of second web 1538 may be about 1.58inches (4 cm) to about 2.36 inches (6 cm), for example two inches (5.08cm). However, these lengths may vary in other embodiments/applications.

In the embodiment illustrated in FIG. 19, the first portion 1531 of thefirst side portion 1526 is embedded in expanded polymer body 12 with thesecond flange 1544 flush with the outer surface 24 of expanded polymerbody 12. The length of the first web 1530 may be about 5.51 inches (14cm) to about 6.30 inches (16 cm), for example six inches (15.24 cm).Further, the length of second web 1538 may be about 1.58 inches (4 cm)to about 2.36 inches (6 cm), for example 2 inches (5.08 cm). However,these lengths may vary in other embodiments/applications.

In the embodiment illustrated in FIG. 23, similar to the embodiment ofFIG. 15, the first portion 1531 of the first side portion 1526 isembedded in the expanded polymer body 12 with the second flange 1544 anda portion of the second web 1538 extending beyond the outer surface 24of the expanded polymer body 12. The length of the first web 1530 may beabout 6.30 inches (16 cm) to about 7.09 inches (18 cm), for exampleseven inches (17.78 cm). Further, the length of second web 1538 may beabout 1.58 inches (4 cm) to about 2.36 inches (6 cm), for example twoinches (5.08 cm). However, these lengths may vary in otherembodiments/applications.

The embodiment illustrated in FIG. 27, similar to the embodiment of FIG.19, the first portion 1531 of the first side portion 1526 is embedded inexpanded polymer body 12 with the second flange 1544 flush with theouter surface 24 of expanded polymer body 12. The length of the firstweb 1530 may be about 6.30 inches (16 cm) to about 7.09 inches (18 cm),for example seven inches (17.78 cm). Further, the length of second web1538 may be about 0.39 inches (1 cm) to about 1.18 inches (3 cm), forexample 1 inch (2.54 cm). However, these lengths may vary in otherembodiments/applications.

In the embodiment illustrated in FIG. 31 the first portion 1531 of thefirst side portion 1526 is embedded in expanded polymer body 12 with thesecond flange 1544 extending slightly beyond the outer surface 24 ofexpanded polymer body 12 such that a bottom surface of second flange1544 is adjacent to outer surface 24. The length of the first web 1530may be about 6.69 inches (17 cm) to about 7.48 inches (19 cm), forexample 7.25 in (18.42 cm). Further, the length of second web 1538 maybe about 0.39 inches (1 cm) to about 1.18 inches (3 cm), for example oneinch (2.54 cm). However, these lengths may vary in otherembodiments/applications.

Referring now to FIGS. 36, 42, 45, 47, 49, 51, 54, 56, 59, 63, 65, 69,71, and 74, in other embodiments of the invention, a “CC-type” stud,denoted generally as 1556, comprises a body 1558 having a length 1557, awidth 1559 and a thickness 41 (see FIGS. 36 and 37). The length 1557 ofthe body 1558 may be about 3.28 feet (1 m) to 9.84 feet (3 m), forexample eight feet (2.44 m). The width 1559 of body 1558 may be about5.90 inches (15 cm) to about 9.84 inches (25 cm), for example eightinches (20.32 cm). However, these lengths may vary in otherembodiments/applications.

In various embodiments, the body 1558 comprises a first side portion1560 and an opposed, second side portion 1562. The first side portion1560 and the second side portion 1562 are positioned along a laterallyextending axis 1561 that traverses the width 1559 of the body 1558. Thefirst side portion 1560 of the body 1558 comprises a first web 1564having a first end 1566 and a second end 1568. The first flange 1570extends generally perpendicularly from the second end 1568 of the firstweb 1564. The first flange 1570 with a first end 1572 adjacent to thefirst web 1564 and a second, opposing end 1574. The first end 1560 ofthe body 1558 can optionally comprise a first return lip 1576 extendinggenerally perpendicularly from the first flange 1570 (see FIG. 36).

The second side portion 1562 of the body 1558 comprises a second flange1578 having a first end 1580 and a second end 1582. The second flange1578 extends generally perpendicularly from the first end 166 of thefirst web 1564. A second web 1584 extends generally perpendicularly fromthe second end 1582 of the second flange 1578. The second web 1584having a first end 1586 and a second end 1588. The second end 1562 ofthe body 1558 also comprises a third flange 1590 extending generallyperpendicularly from the second end 1588 of the second web 1584 and,optionally, a second return lip 1592 extending generally perpendicularlyto the third flange 1590 (see FIG. 36).

In an exemplary embodiment of the “CC-type” stud 1556, such as the oneillustrated in FIG. 42, the first web 1564 has a length of about 3.94inches (10 cm) to about 4.72 inches (12 cm), for example 4.375 inches(11.11 cm). The first flange 1570 has a length of about 1.18 inches (3cm) to about 1.97 inches (5 cm), for example 1.626 in (4.13 cm). Thefirst return lip 1576 has a length of about 0.20 inches (0.5 cm) toabout 0.79 inches (2 cm), for example 0.50 inch (1.27 cm). The secondflange 1578 has a length of about 1.18 inches (3 cm) to about 1.97inches (5 cm), for example 1.626 in (4.13 cm). The second web 1584 has alength of about 3.15 inches (8 cm) to about 3.94 inches (10 cm), forexample 3.626 in (9.21 cm). The third flange 1590 has a length of about1.18 inches (3 cm) to about 1.97 inches (5 cm), for example 1.626 in(4.13 cm). The second return lip 1592 has a length of about 0.20 inches(0.5 cm) to about 0.79 inches (2 cm), for example 0.50 inch (1.27 cm).However, these lengths may vary in other embodiments/applications.

Referring to FIGS. 7-78, the first web 1508, 1530, and 1564 of theembedded reinforcing members which may comprise, for example, studs,joists, etc. have holes 13 or openings along its length to facilitatefusion of the expanded plastic material and to reduce any thermalbridging effects or heat transfer in the reinforcing bars, studs, joistsand/or members.

Expansion holes 13 are useful in that as expanded polymer body 12 ismolded, the polymer matrix expands through expansion holes 13 and theexpanding polymer fuses. This allows the polymer matrix to encase andhold embedded studs 16 by way of the fusion in the expanding polymer. Inan embodiment of the invention, expansion holes 13 can have a flangedand in many cases a rolled flange surface to provide added strength tothe embedded metal studs.

Expansion holes 13 may be configured in a variety of different manners,sizes and shapes including, but not limited to, the followingconfigurations.

Referring now to FIGS. 7 and 8, the first side portion 1504 of body 1502comprises a web 1508 with a plurality of generally circular holes 1594extending along the length of the body 1502. The plurality of holes 1594may be generally evenly spaced along the length of the body 1502. Eachhole of the plurality of holes 1594 may have a diameter of about 0.79inches (2 cm) to about 1.58 inches (4 cm), for example 1.20 inches (3.05cm). However, the sizes, shapes, numbers and spacing arrangement ofholes 1594 may vary without departing from the spirit and scope of thepresent invention. The second end 1506 of the body 1502 comprises web1508 with four elongated, generally oval shaped, utility holes 46. Theutility holes 46 will be discussed in greater detail hereinafter.Likewise, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 9 and 10, the first side portion 1504 of the body1502 comprises a web 1508 with a plurality of holes 1596 along thelength of the body 1502. The holes 1596 may have a generally circularshape and comprise a first series of holes 1598 generally evenly spacedalong the length of the body 1502 and a second series of holes 1600 thatmay be generally evenly spaced along the length of the body 1502. Thefirst series of holes 1598 may be spaced from the second series of holes1600 by a central portion 1602 of the body 1502 that is free of holes.Each of the holes of the first series of holes 1598 and the secondseries of holes 1600 may have a diameter of about 0.79 inches (2 cm) toabout 1.58 inches (4 cm), for example 1.20 inches (3.05 cm). However,the sizes, shapes, numbers and spacing arrangement of these holes mayvary without departing from the spirit and scope of the presentinvention.

The length of the central portion 1602 can vary as desired, for example,the central portion 1602 can be 1/10 to ⅕ of the overall length of thestud. In one embodiment, the central portion 1602 is about 1/7 of thetotal length of the stud. The second side portion 1506 of the bodycomprises web 1508 that may have three, generally oval shaped utilityholes 46. Likewise, the sizes, shapes, numbers and spacing arrangementof these holes may vary without departing from the spirit and scope ofthe present invention.

Referring now to FIGS. 11 and 12, the side portion end 1504 of body 1502comprises a web 1508 that may have six generally circular holes 1604extending along the length of the body 1502. The six holes 1604 may begenerally evenly spaced along the length of the body 1502. Each of thesix holes 1604 may have a diameter of about 0.79 inches (2 cm) to about1.58 inches (4 cm), for example 1.20 inches (3.05 cm). However, thesizes, shapes, numbers and spacing arrangement of these holes may varywithout departing from the spirit and scope of the present invention.The second side portion 1506 of the body 1502 comprises web 1508 thatmay have three, generally oval shaped utility holes 46. Likewise, thesizes, shapes, numbers and spacing arrangement of these holes may varywithout departing from the spirit and scope of the present invention.

Referring now to FIGS. 13 and 14, the first side portion 1504 of body1502 may comprise a web 1508 with six generally circular holes 1606extending along the length of the body 1502. The six holes 1606 may bepositioned along the length of the body 1502 in a first group of twoevenly spaced holes 1608, a second group of two evenly spaced holes 1610and a third group of two evenly spaced holes 1612. The distance betweena second hole 1606 of the first group 1608 and a first hole 1606 of thesecond group 1610 may be the same as the distance from a second hole1606 of the second group 1610 to a first hole 1606 of the third group1612. Each of the six holes 1606 may have a diameter of about 0.79inches (2 cm) to about 1.58 inches (4 cm), for example 1.20 inches (3.05cm). However, the sizes, shapes, numbers and spacing arrangement ofthese holes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIG. 78, the first side portion 1504 of body 1502comprises a web 1508 that may have a first row 1614 of evenly spacedelongated or oval holes 1616, a second row 1618 of evenly spacedelongated or oval holes 1620 and a row 1622 of evenly spaced circularholes 1624 positioned between the first row 1614 of elongated or ovalholes 1616 and the second row 1618 of elongated or oval holes 1620. Eachhole of the row 1622 of circular holes 1624 may have a diameter of about0.79 inches (2 cm) to about 1.58 inches (4 cm), for example 1.20 inches(3.05 cm). Each hole 1620 of the second row 1618 of elongated or ovalholes 1620 may have a length that is equal to the length of each hole1616 of the first row 1614 of elongated or oval holes 1616, although therelative lengths of the respective holes may vary. For instance, eachhole 1620 of the second row 1618 of elongated or oval holes 1620 andeach hole 1616 of the first row 1614 of elongated or oval holes 1616 mayhave a length of about 1.97 inches (5 cm) to about 2.76 inches (7 cm),for example 2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to0.79 inches (2 cm), for example 0.50 inch (1.27 cm). However, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention.

Referring now to FIGS. 17 and 18, the first side portion 1526 of body1524 comprises a plurality of equally spaced, elongated or oval holes1626 extending along a length of the second web 1538 and positionedadjacent to the first flange 1536, and a plurality of equally spaced,generally circular holes 1628 extending along a length of the first web1530 on the other side of the first flange 1536. Each hole of theplurality of elongated or oval holes 1626 may have a length of about1.97 inches (5 cm) to about 2.76 inches (7 cm), for example 2.5 inches(6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79 inches (2 cm),for example 0.50 inch (1.27 cm). Each hole of the plurality of circularholes 1628 may have a diameter of about 0.79 inches (2 cm) to about 1.58inches (4 cm), for example 1.20 inches (3.05 cm). However, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondside portion 1528 of the body 1524 may comprise four, generally ovalshaped utility holes 46 extending along the length of the first web1530. Likewise, the sizes, shapes, numbers and spacing arrangement ofthese holes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 21 and 22, the first side portion 1526 of body1524 may comprise a plurality of equally spaced, elongated or oval holes1630 extending along a length of the second web 1538 and positioned inthe center of the second web 1538, and a plurality of equally spaced,generally circular holes 1632 extending along a length of the first web1530. Each hole of the plurality of elongated or oval holes 1630 mayhave a length of about 1.97 inches (5 cm) to about 2.76 inches (7 cm),for example 2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to0.79 inches (2 cm), for example 0.50 inch (1.27 cm). Each hole of theplurality of circular holes 1632 may have a diameter of about 0.79inches (2 cm) to about 1.58 inches (4 cm), for example 1.20 inches (3.05cm). However, the sizes, shapes, numbers and spacing arrangement ofthese holes may vary without departing from the spirit and scope of thepresent invention. The second side portion 1528 of the body 1524 maycomprise four, generally oval shaped utility holes 46 extending alongthe length of the first web 1530. Likewise, the sizes, shapes, numbersand spacing arrangement of these holes may vary without departing fromthe spirit and scope of the present invention.

Referring now to FIGS. 25 and 26, the first side portion 1526 of body1524 may comprise a plurality of equally spaced, elongated or oval holes1634 extending along a length of the second web 1538 and adjacent to thefirst flange 1536, and a plurality of equally spaced, generally circularholes 1636 extending along a length of the first web 1530. Each hole ofthe plurality of elongated or oval holes 1634 may have a length of about1.97 inches (5 cm) to about 2.76 inches (7 cm), for example 2.5 inches(6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79 inches (2 cm),for example 0.50 inch (1.27 cm). Each hole of the plurality of circularholes 1636 may have a diameter of about 0.79 inches (2 cm) to about 1.58inches (4 cm), for example 1.20 inches (3.05 cm). However, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondside portion 1528 of the body 1524 may comprise three, generally ovalshaped utility holes 46 extending along the length of the first web1530. Likewise, the sizes, shapes, numbers and spacing arrangement ofthese holes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 29 and 30, the first side portion 1526 of body1524 may comprise a plurality of equally spaced, elongated or oval holes1638 extending along a length of the second web 1538 and positioned inthe center of the second web 1538. The first side portion 1526 may alsocomprise a plurality of equally spaced, generally circular holes 1640extending along a length of the first web 1530. Each hole of theplurality of elongated or oval holes 1638 may have a length of about1.97 inches (5 cm) to about 2.76 inches (7 cm), for example 2.5 inches(6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79 inches (2 cm),for example 0.50 inch (1.27 cm). Each hole of the plurality of circularholes 1640 may have a diameter of about 0.79 inches (2 cm) to about 1.58inches (4 cm), for example 1.20 inches (3.05 cm). However, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondside portion 1528 of the body 1524 may comprise three, generally ovalshaped utility holes 46 extending along the length of the first web1530. Likewise, the sizes, shapes, numbers and spacing arrangement ofthese holes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 33 and 34, the first side portion 1526 of body1524 may comprise a plurality of equally spaced, elongated or oval holes1642 extending along a length of the second web 1538 and positioned inthe center of the second web 1538, and a plurality of equally spaced,generally circular holes 1644 extending along a length of the first web1530. Each hole of the plurality of elongated or oval holes 1642 mayhave a length of about 1.97 inches (5 cm) to about 2.76 inches (7 cm),for example 2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to0.79 inches (2 cm), for example 0.50 inch (1.27 cm). Each hole of theplurality of circular holes 1644 may have a diameter of about 0.79inches (2 cm) to about 1.58 inches (4 cm), for example 1.20 inches (3.05cm). However, the sizes, shapes, numbers and spacing arrangement ofthese holes may vary without departing from the spirit and scope of thepresent invention. The second side portion 1528 of the body 1524 maycomprise three, generally oval shaped utility holes 46 extending alongthe length of the first web 1530. Likewise, the sizes, shapes, numbersand spacing arrangement of these holes may vary without departing fromthe spirit and scope of the present invention.

Referring now to FIGS. 37 and 38, the first side portion 1560 of body1558 may comprise a first row 1646 of equally spaced, elongated or ovalholes 1648, a second row 1650 of equally spaced, elongated or oval holes1652 and a third row 1654 of equally spaced, elongated or oval holes1656. Each row 1646, 1650, 1654 extends along a length of the first web1564. The second row 1650 of equally spaced, elongated or oval holes1652 may be offset with respect to the first and third rows 1646, 1654of equally spaced, elongated or oval holes 1648, 1656, i.e., the centerof holes 1648, 1656 are aligned and the centers of holes 1652 are offsetwith respect thereto. Each hole of each row 1646, 1650, 1654 ofelongated or oval holes 1648, 1652, 1656 may have a length of about 1.97inches (5 cm) to about 2.76 inches (7 cm), for example 2.5 inches (6.35cm), and a width of 0.20 inches (0.5 cm) to 0.79 inches (2 cm), forexample 0.50 inch (1.27 cm). However, the sizes, shapes, numbers andspacing arrangement of these holes may vary without departing from thespirit and scope of the present invention. The second side portion 1562of the body 1558 may comprise four, generally oval shaped utility holes46 extending along the length of the second web 1584. Likewise, thesizes, shapes, numbers and spacing arrangement of these holes may varywithout departing from the spirit and scope of the present invention.Further, the second web portion 1584 has a length that is greater thanthe length of the first web portion 1564, as shown in FIG. 38, therebycreating a notch. The notch allows for secure attachment to a framingsystem.

Referring now to FIGS. 39 and 40, the first side portion 1560 of body1558 may comprise a first row 1658 of equally spaced, elongated or ovalholes 1660, a second row 1662 of equally spaced, elongated or oval holes1664 and a third row 1666 of equally spaced, elongated or oval holes1668. Each row 1658, 1662, 1666 extends along a length of the first web1564. The second row 1662 of equally spaced, elongated or oval holes1664 may be offset with respect to the first and third rows 1658, 1666of equally spaced, elongated or oval holes 1660, 1668. Each hole of eachrow 1658, 1662, 1666 of elongated or oval holes 1660, 1664, 1668 mayhave a length of about 1.97 inches (5 cm) to about 2.76 inches (7 cm),for example 2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to0.79 inches (2 cm), for example 0.50 inch (1.27 cm). However, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondside portion 1562 of the body 1558 may comprise three, generally ovalshaped utility holes 46 extending along the length of the second web1584. Likewise, the sizes, shapes, numbers and spacing arrangement ofthese holes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 41-44, the first side portion 1560 of body 1558may comprise a first row 1670 of equally spaced, elongated or oval holes1672, a second row 1674 of equally spaced, elongated or oval holes 1676and a third row 1678 of equally spaced, elongated or oval holes 1680.See FIG. 43. Each row 1670, 1674, 1678 extends along a length of thefirst web 1564. The second row 1674 of equally spaced, elongated or ovalholes 1676 may be offset with respect to the first and third rows 1670,1678 of equally spaced, elongated or oval holes 1672, 1680. Each hole ofeach row 1670, 1674, 1678 of elongated or oval holes 1672, 1676, 1680may have a length of about 1.97 inches (5 cm) to about 2.76 inches (7cm), for example 2.36 inches (6 cm), and a width of 0.20 inches (0.5 cm)to 0.79 inches (2 cm), for example 0.591 in (1.5 cm). However, thesizes, shapes, numbers and spacing arrangement of these holes may varywithout departing from the spirit and scope of the present invention.The second side portion 1562 of the body 1558 may comprise three,generally oval shaped knockout holes 46 extending along the length ofthe second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 45 and 46, the first side portion 1560 of body1558 may comprise a first row 1682 of equally spaced, elongated or ovalholes 1684, a second row 1686 of equally spaced, elongated or oval holes1688 and a third row 1690 of equally spaced, elongated or oval holes1692. Each row 1682, 1686, 1690 extends along a length of the first web1564. The second row 1686 of equally spaced, elongated or oval holes1688 may be offset with respect to the first and third rows 1682, 1690of equally spaced, elongated or oval holes 1684, 1692. Also, each hole1688 of the second row 1686 of elongated or oval holes 1688 may have alength that is greater than the length of each hole of the first andthird rows 1682, 1690 of elongated or oval holes 1684, 1692. Each holeof each row 1682, 1690 of elongated or oval holes 1684, 1692 may have alength of about 1.97 inches (5 cm) to about 2.76 inches (7 cm), forexample 2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to0.79 inches (2 cm), for example 0.50 inch (1.27 cm). Each hole of row1686 of elongated or oval holes 1688 may have length of about 7.87 in(20 cm) to about 9.45 in (24 cm), for example 8.50 in (21.6 cm).However, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention. The second side portion 1562 of the body 1558 maycomprise three, generally oval shaped knockout holes 46 extending alongthe length of the second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 47 and 48, the first side portion 1560 of body1558 may comprise a first row 1693 of equally spaced, elongated or ovalholes 1694, a second row 1695 of equally spaced, elongated or oval holes1696, a third row 1697 of equally spaced, elongated or oval holes 1698,a fourth row 1699 of equally spaced, elongated or oval holes 1700 and afifth row 1701 of equally spaced, elongated or oval holes 1702 extendingalong a length of the first web 1564. The second and fourth rows 1695and 1699 may be offset with respect to the first, third and fifth rows1693, 1697 and 1701. Each hole of each row 1693, 1695, 1697, 1699, 1701of elongated or oval holes 1694, 1696, 1698, 1700 and 1702 may have alength of about 4.33 in (11 cm) to about 5.51 inches (14 cm), forexample five inches (12.7 cm), and a width of 0.10 inches (0.25 cm) to0.39 inches (1 cm), for example 0.25 inches (0.635 cm). However, thesizes, shapes, numbers and spacing arrangement of these holes may varywithout departing from the spirit and scope of the present invention.The second side portion 1562 of the body 1558 may comprise three,generally oval shaped knockout holes 46 extending along the length ofthe second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 49 and 50, the first side portion 1560 of body1558 may comprise a first row 1703 of equally spaced, elongated orrectangular holes 1704, a second row 1705 of equally spaced, elongatedor rectangular holes 1706 and a third row 1707 of equally spaced,elongated or rectangular holes 1708 extending along a length of thefirst web 1564. Each hole of the second row of elongated or rectangularholes 1706 may have a length that is greater than the length of eachhole of the first and third rows of elongated or rectangular holes 1704and 1706. Each hole of each row 1703, 1707 of elongated or rectangularholes 1704, 1708 may have a length of about 1.97 inches (5 cm) to about2.76 inches (7 cm), for example 2.5 inches (6.35 cm), and a width ofabout 0.20 inches (0.5 cm) to about 0.79 inches (2 cm), for example 0.50inch (1.27 cm). Each hole of row 1705 of elongated or rectangular holes1688 may have length of about 10.63 in (27 cm) to about 15.60 in (32cm), for example 11.5 in (29.2 cm) and a width of about 0.20 inches (0.5cm) to about 0.79 inches (2 cm), for example 0.50 inch (1.27 cm).However, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention. The second side portion 1562 of the body 1558 maycomprise three, generally oval shaped knockout holes 46 extending alongthe length of the second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 51-53, the first side portion 1560 of body 1558may comprise a row of generally alternating first generally triangularslots 1710 and second generally triangular slots 1712 extending along alength of the first web 1564. The first triangular slots 1710 maycomprise a base 1714 positioned generally parallel to an intersectingedge between the first web 1564 and the first flange 1570 of the firstend 1560 of the body 1558 and an apex 1716 oriented toward the secondflange 1578 of the second end 1562 of the body 1558. The secondtriangular slots 1712 may comprise a base 1718 positioned generallyparallel to an intersecting edge between the first web 1564 and secondflange 1578 of the second end 1562 of the body 1558 and an apex 1720oriented toward the first flange 1570 of the first end 1560 of the body1558. The first triangular slots 1710 and second triangular slots 1712may generally comprise equilateral triangles with each edge of eachtriangular slot 1710, 1712 having a length of about 1.58 inches (4 cm)to about 2.36 inches (6 cm), for example two inches (5.13 cm). However,the sizes, shapes, numbers and spacing arrangement of these holes mayvary without departing from the spirit and scope of the presentinvention. The second side portion 1562 of the body 1558 may comprisethree, generally oval shaped knockout holes 46 extending along thelength of the second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 54 and 55, the first side portion 1560 of body1558 may comprise a first row 1721 of elongated or oval holes 1722, asecond row 1723 of elongated or oval holes 1724 with each hole having alength that is less than the length of each hole of the first row ofelongated or oval holes 1722, a row of generally alternating firsttriangular slots 1726 and second triangular slots 1728, a third row 1729of elongated or oval holes 1730 with each hole having a length that isequal to the length of each hole of the second row 1723 of elongated oroval holes 1724, and a fourth row 1731 of elongated or oval holes 1732with each hole having a length that is equal to the length of each holeof the first row 1721 of elongated or oval holes 1722. Each row of holesextends along a length of the first web 1564. Each hole of the first row1721 of elongated or oval holes 1722 and the fourth row 1731 ofelongated or oval holes 1732 may have a length of about 5.51 inches (14cm) to about 6.30 inches (16 cm), for example six inches (15.24 cm), anda width of about 0.10 inches (0.25 cm) to about 0.39 inches (1 cm), forexample 0.25 inches (0.635 cm). Each hole of the second row 1723 ofelongated or oval holes 1724 and the third row 1729 of elongated or ovalholes 1730 may have a length of about 0.591 in (1.5 cm) to about 1.378in (3.5 cm), for example one inch (2.54 cm), and a width of about 0.10inches (0.25 cm) to about 0.39 inches (1 cm), for example 0.25 inches(0.635 cm). However, the sizes, shapes, numbers and spacing arrangementof these holes may vary without departing from the spirit and scope ofthe present invention. The first triangular slots 1726 may comprise abase 1734 positioned generally parallel to an intersecting edge betweenthe first web 1564 and the first flange 1570 of the first end 1560 ofthe body 1558 and an apex 1736 oriented toward the second flange 1578 ofthe second end 1562 of the body 1558. The second triangular slots 1728may comprise a base 1738 positioned generally parallel to anintersecting edge between the first web 1564 and second flange 1578 ofthe second end 1562 of the body 1558 and an apex 1740 oriented towardthe first flange 1570 of the first end 1560 of the body 1558. The firsttriangular slots 1710 and second triangular slots 1712 may generallycomprise equilateral triangles with each edge of each triangular slot1710, 1712 having a length of about 1.58 inches (4 cm) to about 2.36inches (6 cm), for example two inches (5.13 cm). However, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondside portion 1562 of the body 1558 may comprise three, generally ovalshaped knockout holes 46 extending along the length of the second web1584 to be used for utilities or structural bracing/spacer members.Likewise, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 57 and 58, the first side portion 1560 of body1558 may comprise a first row 1741 of elongated or oval holes 1742, arow of generally alternating first triangular slots 1744 and secondtriangular slots 1746, and a second row 1747 of elongated or oval holes1748 with each hole having a length that is equal to the length of eachhole of the first row of elongated or oval holes 1742. Each row of holesextends along a length of the first web 1564. Each hole of the first row1741 of elongated or oval holes 1742 and second row 1747 of elongated oroval holes 1748 may have a length of about 3.15 inches (8 cm) to about3.94 inches (10 cm), for example 3.54 in (9 cm), and a width of about0.10 inches (0.25 cm) to about 0.39 inches (1 cm), for example 0.25inches (0.635 cm). However, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention. The first triangular slots 1744 maycomprise a base 1750 positioned generally parallel to an intersectingedge between the first web 1564 and the first flange 1570 of the firstend 1560 of the body 1558 and an apex 1752 oriented toward the secondflange 1578 of the second end 1562 of the body 1558. The secondtriangular slots 1746 may comprise a base 1754 positioned generallyparallel to an intersecting edge between the first web 1564 and secondflange 1578 of the second end 1562 of the body 1558 and an apex 1756oriented toward the first flange 1570 of the first end 1560 of the body1558. The first triangular slots 1710 and second triangular slots 1712may generally comprise equilateral triangles with each edge of eachtriangular slot 1710, 1712 having a length of about 1.58 inches (4 cm)to about 2.36 inches (6 cm), for example two inches (5.13 cm). However,the sizes, shapes, numbers and spacing arrangement of these holes mayvary without departing from the spirit and scope of the presentinvention. The second side portion 1562 of the body 1558 may comprisesthree, generally oval shaped knockout holes 46 extending along thelength of the second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 59 and 60, the first side portion 1560 of body1558 may comprise a first row 1757 of equally spaced, elongated or ovalholes 1758, a second row 1759 of equally spaced, elongated or oval holes1760, and a third row 1761 of equally spaced, elongated or oval holes1762. Each row of holes extends along a length of the first web 1564.The second row of holes 1760 may be offset with respect to the first andthird rows of hole 1758, 1762. Each hole of each row 1757, 1759, 1760 ofelongated or oval holes 1758, 1760, 1762 may have a length of about 7.48inches (19 cm) to about 8.27 in (21 cm), for example eight inches (20.32cm), and a width of about 0.20 inches (0.5 cm) to about 0.79 inches (2cm), for example 0.50 inch (1.27 cm). However, the sizes, shapes,numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondside portion 1562 of the body 1558 may comprise three, generally ovalshaped knockout holes 46 extending along the length of the second web1584 to be used for utilities or structural bracing/spacer members.Likewise, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 61 and 62, the first side portion 1560 of body1558 may comprise a first row 1763 of equally spaced, elongated or ovalholes 1764, a second row 1765 of equally spaced, elongated or oval holes1766, and a 1767 third row of equally spaced, elongated or oval holes1768. Each row of holes extends along a length of the first web 1564.The second row of holes 1766 may be offset with respect to the first andthird rows of holes 1764, 1768. Each hole of each row 1763, 1765, 1767of elongated or oval holes 1764, 1766, 1768 may have a length of about7.48 inches (19 cm) to about 8.27 in (21 cm), for example eight inches(20.32 cm), and a width of about 0.20 inches (0.5 cm) to about 0.79inches (2 cm), for example 0.50 inch (1.27 cm). However, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondflange 1578 may comprise additional slots 1769 extending along a lengththereof. The additional slots 1769 provide for a thermal break. Thesecond side portion 1562 of the body 1558 may comprise three, generallyoval shaped knockout holes 46 extending along the length of the secondweb 1584 to be used for utilities or structural bracing/spacer members.Likewise, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 63 and 64, the first side portion 1560 of body1558 may comprise a first row 1771 of equally spaced, generallyelongated or rectangular holes 1770, a second row 1773 of equallyspaced, generally elongated or rectangular holes 1772, a third row 1775of equally spaced, generally elongated or rectangular holes 1774, afourth row 1777 of equally spaced, generally elongated or rectangularholes 1776, and a fifth row 1779 of equally spaced, generally elongatedor rectangular holes 1778. Each row extends along a length of the firstweb 1564. As shown in FIG. 63, in various embodiments, the holes 1770may be formed by punching corresponding tabs 1771′ in the first web1564. Likewise, the holes 1774 may be formed by punching, cutting, etc.corresponding tabs 1775′ in the first web 1564. Holes 1778 may be formedby punching, cutting, etc. corresponding tabs 1779′ in the first web1564. One skilled in the art will appreciate that the tabs 1771′, 1775′and 1779′ serve to strengthen the first web 1564. Each hole of thefirst, third and fifth rows 1771, 1775, 1779 of elongated holes 1770,1774, 1778 may have a smaller cross-sectional width and shorter lengththan the holes of the second and forth rows 1773, 1777 of elongatedholes 1772, 1776. Each hole of the first, third and fifth rows 1771,1775, 1779 of elongated holes 1770, 1774, 1778 may have a length ofabout 2.36 inches (6 cm) to about 3.15 inches (8 cm), for example threeinches (7.62 cm), and a width of about 0.20 inches (0.5 cm) to about0.30 in (0.75 cm), for example 0.26 in (0.65 cm) cm. Each hole of thesecond and fourth rows 1773, 1777 of elongated holes 1772, 1776 has alength of about 7.48 inches (19 cm) to about 8.27 in (21 cm), forexample eight inches (20.32 cm), and a width of about 0.20 inches (0.5cm) to about 0.79 inches (2 cm), for example 0.50 inch (1.27 cm).However, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention. The second side portion 1562 of the body 1558 maycomprise three, generally oval shaped or otherwise elongated knockoutholes 46 extending along the length of the second web 1584 to be usedfor utilities or structural bracing/spacer members. Likewise, the sizes,shapes, numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention.

Referring now to FIGS. 65 and 66, the first side portion 1560 of body1558 may comprise a first row 1781 of equally spaced, generallyelongated or rectangular holes 1780, a second row 1783 of equallyspaced, generally elongated or rectangular holes 1782, a third row 1785of equally spaced, generally elongated or rectangular holes 1784, afourth row 1787 of equally spaced, generally elongated or rectangularholes 1786, and a fifth row 1789 of equally spaced, generally elongatedor rectangular holes 1788. Each row extends along a length of the firstweb 1564. As can be seen in FIG. 65, in various embodiments, the holes1780 may be formed by punching, cutting, etc. corresponding tabs 1781′in the first web 1564. Likewise, the holes 1784 may be formed bypunching, cutting, etc. corresponding tabs 1785′ in the first web 1564.Holes 1788 may be formed by punching cutting, punching, etc.corresponding tabs 1789′ in the first web 1564. One skilled in the artwill appreciate that the tabs 1781′, 1785′, and 1789′ serve tostrengthen the first web 1564. Each hole of the first, third and fifthrows 1781, 1785, 1789 of elongated holes 1780, 1784, 1788 may have asmaller cross-sectional width and shorter length than the holes of thesecond and forth rows 1783, 1787 of elongated holes 1782, 1786. Eachhole of the first, third and fifth rows 1781, 1785, 1789 of elongatedholes 1780, 1784, 1788 may have a length of about 2.36 inches (6 cm) toabout 3.15 inches (8 cm), for example three inches (7.62 cm), and awidth of about 0.20 inches (0.5 cm) to about 0.30 in (0.75 cm), forexample 0.26 in (0.65 cm) cm. Each hole of the second and fourth rows1783, 1787 of elongated holes 1782, 1786 may have a length of about 7.48inches (19 cm) to about 8.27 in (21 cm), for example eight inches (20.32cm), and a width of about 0.20 inches (0.5 cm) to about 0.79 inches (2cm), for example 0.50 inch (1.27 cm). However, the sizes, shapes,numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondflange 1578 may comprise additional slots 1810 extending along a lengththereof. The additional slots 1810 provide for a thermal break. Thesecond side portion 1562 of the body 1558 may comprise three, generallyoval shaped or otherwise elongated knockout holes 46 extending along thelength of the second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 67 and 68, the first side portion 1560 of body1558 may comprise a first row 1791 of equally spaced, generallyelongated or rectangular holes 1790, a second row 1793 of equallyspaced, generally elongated or rectangular holes 1792 and a third row1795 of equally spaced, generally elongated or rectangular holes 1794extending along the length of the first web 1564. As shown in FIG. 67,in various embodiments, the holes 1790 may be formed by punching,cutting, etc. corresponding tabs 1791′ in the first web 1564. Likewise,the holes 1794 may be formed by punching, cutting, etc. correspondingtabs 1795′ in the first web 1564. One skilled in the art will appreciatethat the tabs 1791′ and 1795′ serve to strengthen the first web 1564.Each hole of the first and third rows 1791, 1795 of elongated holes1790, 1794 may have a smaller cross sectional width and shorter lengththan each hole of the second row 1793 of elongated or rectangular holes1792. Each hole of the first and third rows 1791, 1795 of elongated orrectangular holes 1790, 1794 may have a length of about 2.36 inches (6cm) to about 3.15 inches (8 cm), for example three inches (7.62 cm), anda width of about 0.20 inches (0.5 cm) to about 0.30 in (0.75 cm), forexample 0.26 in (0.65 cm) cm. Each hole of the second row 1793 ofelongated or rectangular holes 1792 may have a length of about 7.48inches (19 cm) to about 8.27 in (21 cm), for example eight inches (20.32cm), and a width of about 0.20 inches (0.5 cm) to about 0.79 inches (2cm), for example 0.50 inch (1.27 cm). However, the sizes, shapes,numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondflange 1578 may comprise additional slots 1810 extending along a lengththereof. The additional slots 1810 provide for a thermal break. Thesecond side portion 1562 of the body 1558 may comprise three, generallyoval shaped or otherwise elongated utility holes 46 extending along thelength of the second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 69 and 70, the first side portion 1560 of body1558 may comprise a first row 1797 of elongated or oval holes 1796, asecond row 1799 of elongated or oval holes 1798 and a row of generallytrapezoidally shaped holes 1801 positioned between the first row 1797 ofelongated holes 1796 and the second row 1799 of elongated holes 1798.Each row extends along a length of the first web 1564. Each hole of thesecond row of 1799 elongated holes 1798 may have a length that is equalto the length of each hole of the first row 1797 of elongated holes1796. Each hole of the first and second rows 1797, 1799 of elongatedholes 1796, 1798 may have a length of about 3.50 in (8.89 cm) to about7.50 in (19.05 cm), for example six inches (15.24 cm), and a width ofabout 0.25 inches (0.635 cm) to about 0.79 inches (2 cm), for example0.50 inch (1.27 cm). Each of the trapezoidally shaped elongated holes1801 may have an area of about 1.55 in² (10 cm²) to about 9.30 in² (60cm²), for example 6.665 in² (43 cm²). However, the sizes, shapes,numbers and spacing arrangement of these holes may vary withoutdeparting from the spirit and scope of the present invention. The secondside portion 1562 of the body 1558 may comprise three, generally ovalshaped or otherwise elongated utility holes 46 extending along thelength of the second web 1584 to be used for utilities or structuralbracing/spacer members. Likewise, the sizes, shapes, numbers and spacingarrangement of these holes may vary without departing from the spiritand scope of the present invention.

Referring now to FIGS. 71 and 72, the first side portion 1560 of body1558 may comprise a first row 1803 of elongated or oval holes 1800, asecond row 1805 of elongated or oval holes 1802 and a row of generallytrapezoidally shaped holes 1804 positioned between the first row 1803 ofelongated holes 1800 and the second row 1805 of elongated holes 1802.Each row extends along a length of the first web 1564. Each hole of thesecond row 1805 of elongated holes 1802 may have a length that is equalto the length of each hole of the first row 1803 of elongated holes1800. Each hole of the first and second rows 1803, 1805 of elongatedholes 1800, 1802 may have a length of about 3.50 in (8.89 cm) to about7.50 in (19.05 cm), for example 5.50 in (13.97 cm), and a width of about0.25 inches (0.635 cm) to about 0.79 inches (2 cm), for example 0.50inch (1.27 cm). Each of the trapezoidally shaped elongated holes 1801may have an area of about 1.55 in² (10 cm²) to about 9.30 in² (60 cm²),for example 6.665 in² (43 cm²). However, the sizes, shapes, numbers andspacing arrangement of these holes may vary without departing from thespirit and scope of the present invention. The second side portion 1562of the body 1558 may comprise three, generally oval shaped or otherwiseelongated utility holes 46 extending along the length of the second web1584 to be used for utilities or structural bracing/spacer members.Likewise, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention.

Referring now to FIGS. 74 and 75, the first side portion 1560 of body1558 may comprise a first row 1807 of evenly spaced elongated or ovalholes 1804, a second row 1809 of evenly spaced elongated or oval holes1806, and a row 1811 of evenly spaced circular holes 1808 positionedbetween the first row 1807 of elongated holes 1804 and the second row1809 of elongated holes 1806. Each row extends along a length of thefirst web 1564. Each hole of the second row 1809 of evenly spacedelongated holes 1806 may have a length that is equal to the length ofeach hole of the first row 1807 of elongated holes 1804. For instance,each hole of the second row 1809 of elongated holes 1806 and each holeof the first row 1807 of elongated holes 1804 may have a length of about1.97 inches (5 cm) to about 2.76 inches (7 cm), for example 2.5 inches(6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79 inches (2 cm),for example 0.50 inch (1.27 cm). However, the sizes, shapes, numbers andspacing arrangement of these holes may vary without departing from thespirit and scope of the present invention. The second side portion 1562of the body 1558 may comprise four, generally oval shaped or otherwiseelongated knockout holes 46 extending along the length of the second web1584 to be used for utilities or structural bracing/spacer members.Likewise, the sizes, shapes, numbers and spacing arrangement of theseholes may vary without departing from the spirit and scope of thepresent invention.

The reinforcing member has a second or exposed side portion extendingaway from the first surface of the central body. For example, as shownin FIGS. 1 and 4, embedded metal studs 14 and 16 have exposed secondside portions 26 and 28 respectively that extend from inner surface 30of expanded polymer body 12.

Exposed side portions 26 and 28 can extend at least 0.39 inches (1 cm),in some cases at least 0.79 inches (2 cm), and in other cases at least1.18 inches (3 cm) away from inner surface 30 of expanded polymer body12. Also, exposed side portions 26 and 28 can extend up to 1.97 ft (60cm), in some cases up to 15.748 in (40 cm), and in other cases up to7.87 in (20 cm) away from inner surface 30 of expanded polymer body 12.Exposed side portions 26 and 28 can extend any of the distances or canrange between any of the distances recited above from inner surface 30.

Referring now to FIGS. 79 and 80, inserts can be added to expandedpolymer body 12 to allow for more secure anchoring positions. Forexample, with reference to FIG. 79, one or more attachment members 7900may be embedded in expanded polymer body 12 to allow for the attachmentof a finish surface 475 thereto. In various embodiments, such attachmentmembers may comprise, for example, U-channel studs, furring strips, etc.With reference to FIG. 80, high density foam 7902 may be embedded inexpanded polymer body 12 flush with outer surface 24. The foam providesfor a more secure anchoring position as well as aid in locating theembedded studs 14 and 16.

Referring to FIGS. 7-14, 17, 18, 21, 22, 25, 26, 29, 30, 33, 34, 37-40,43, 46, 48, 50, 52, 53, 55, 57, 58, 60, 62, 64, 66, 68, 70, 72, 75, 78and 91, embedded metal studs 14 and 16 can have utility holes 46 spacedalong the length of exposed side portions 26 and 28 (i.e., thestructural portion of the stud). Utility holes 46 may be useful forrunning utilities such as wiring for electricity, telephone, cabletelevision, speakers, and other electronic devices, gas lines and waterlines. Utility holes 46 can have various cross-sectional shapes,non-limiting examples being round, oval, elliptical, square,rectangular, triangular, hexagonal or octagonal. The cross-sectionalarea of utility holes 46 can also vary independently one from another orthey can be uniform. The cross-sectional area of utility holes 46 islimited by the dimensions of embedded metal studs 14 and 16, as utilityholes 46 will fit within their dimensions and not significantly detractfrom their structural integrity and strength. The cross-sectional areaof utility holes 46 can independently be at least 1, in some cases atleast 2, and in other cases at least 0.775 in² (5 cm²) and can be up to30, in some cases up to 25, in other cases up to 3.10 in² (20 cm²). Thecross-sectional area of openings 18 can independently be any value orrange between any of the values recited above. Typically, the number ofutility holes ranges from 1 to 5, for example 3 or 4. However, othersizes, shapes, numbers and spacing arrangements could conceivable beemployed in alternative embodiments.

In various embodiments of the invention, utility holes 46 can have aflanged portion around their respective perimeters and in many cases arolled flange surface to reinforce the area around the holes. Theflanged holes provide added strength to allow for the use of lightergauge materials to achieve the same structural properties.

The spacing between each of embedded metal studs 14 and 16 is typicallyadapted to be consistent with local construction codes or methods, butcan be modified to suit special needs. As such, the spacing between themetal studs can be at least 25 and in some cases at least 30 cm and canbe up to 110, in some cases up to 100, in other cases up to 75, and insome instances up to 1.97 ft (60 cm) measured from a midpoint of exposedend 26 to a midpoint of exposed end 28. The spacing between embeddedmetal studs 14 and 16 can be any distance or range between any of thedistances recited above.

As shown in FIG. 1, expanded polymer body 12 can extend for a distancewith alternating embedded metal studs 14 and 16 placed therein. Thelength of wall unit 10 can be any length that allows for safe handlingand minimal damage to wall unit 10 while it is being transported andinstalled. The length of wall unit 10 can typically be at least 1, insome cases at least 1.5, and in other cases at least 6.56 feet (2 m) andcan be up to 25, in some cases up to 20, in other cases up to 15, insome instances up to 10 and in other instances up to 16.40 feet (5 m).The length of wall unit 10 can be any value or can range between any ofthe values recited above. In some embodiments of the invention, each endof wall unit 10 is terminated with an embedded metal stud.

The height of wall unit 10 can be any height that allows for safehandling and minimal damage to wall unit 10. The height of wall unit 10is determined by the length of embedded metal studs 14 and 16. Theheight of wall unit 10 can be at least 1 and in some cases at least 4.92feet (1.5 m) and can be up to 9.84 feet (3 in) and in some cases up to8.20 feet (2.5 m). In some instances, in order to add stability to wallunit 10, reinforcing cross-members known as spacer bars (not shown) canbe attached to embedded metal studs 14 and 16. The height of wall unit10 can be any value or can range between any of the values recitedabove.

As shown in FIG. 1, expanded polymer body 12 has a finite length and canhave a male terminal end 21 that includes forward edge 23 and trailingedge 25 and a receiving end 27 which includes recessed section 29 andextended section 31, which is adapted to receive forward edge 23, andtrailing edge 25. Typically, lengths of wall units 10 are interconnectedby inserting a forward edge 23 from a first wall unit 10 into a recessedsection 29 a second wall unit 10. In this manner, a larger wall sectioncontaining any number of wall units can be assembled and/or arrayed.

Various configurations for interconnecting wall units 10 have beencontemplated. Referring now to FIG. 1, the expanded polymer body 12 ofwall unit 10 has a first end 17 configured to include a male “tongue” orterminal end 21 and a second end 19 configured to include a female“groove” or recessed section 29 that facilitates a “tongue and groove”union of two matching wall units 10. Typically the tongue and grooveunion provides a flat surface at the union to allow for easy applicationof sealing tape to further seal the union or joint if desired.

Referring now to FIG. 4, the first end 17 of expanded polymer body 12may include a plurality of “tongue” portions 4000 designed tointerconnect with corresponding grooves 4002 formed in the second end 19of expanded polymer body 12. “Tongue” portions 4000 may have a generallypyramidal shape that corresponds with the shape of grooves 4002 therebyproviding a smooth flat surface when two wall units 10 areinterconnected.

Referring now to FIG. 81, the first end 17 of expanded polymer body 12may include a protruding portion 8100 adjacent to outer surface 24 and arecessed portion 8102 adjacent to inner surface 30 and the second end 19includes a corresponding protruding portion (not shown) adjacent toinner surface 30 and a corresponding recessed portion (not shown)positioned adjacent to outer surface 30. Each of the protruding portionsmay have a generally pyramidal shape that corresponds with the shape ofeach of the recessed portions. The protruding portion 8100 is designedto align with a corresponding recessed portion when two wall units 10are interconnected thereby providing a substantially smooth flat wallsurface.

Referring now to FIG. 82, the first end 17 of expanded polymer body 12may include a protruding portion 8200 and the second end 19 includes acorresponding recessed portion (not shown). The protruding portion mayhave a generally semicircular shape that corresponds with a shape of thecorresponding recessed portion. The protruding portion 8200 is designedto align with a corresponding recessed portion when two wall units 10are interconnected thereby providing a substantially smooth flat wallsurface.

Referring now to FIG. 83A, the first end 17 of expanded polymer body 12may include a protruding portion 8300 adjacent to outer surface 24 and arecessed portion 8302 adjacent to inner surface 30 and the second end 19includes a corresponding protruding portion (not shown) adjacent toinner surface 30 and a corresponding recessed portion (not shown)positioned adjacent to outer surface 30. Each of the protruding portionsmay have a generally semicircular shape that corresponds with the shapeof each of the recessed portions. The protruding portion 8300 isdesigned to align with a corresponding recessed portion when two wallunits 10 are interconnected thereby providing a substantially smoothflat wall surface.

Referring now to FIG. 83B, the first end 17 of expanded polymer body 12may include a protruding portion 8304 and the second end 19 includes acorresponding recessed portion (not shown). The protruding portion mayhave a generally rectangular shape that corresponds with a shape of thecorresponding recessed portion. The protruding portion 8304 is designedto align with a corresponding recessed portion when two wall units 10are interconnected thereby providing a substantially smooth flat wallsurface.

Referring now to FIG. 83C, the first end 17 of expanded polymer body 12may include a protruding portion 8306 adjacent to outer surface 24 andthe second end 19 includes protruding portion (not shown) positionedadjacent to inner surface 30. Each of the protruding portions may have agenerally rectangular shape. The protruding portion 8306 is designed toadjoin with the protruding portion of the second end 19 when two wallunits 10 are interconnected thereby providing a substantially smoothflat wall surface.

Referring now to FIGS. 84-87, the first end 17 and the second end 19 ofexpanded polymer body 12 may each include a generally semicircularrecess 8400. When two wall units 10 are placed adjacent to each other,the recess on the first end 17 of a first wall unit 10 and the recess onthe second end 19 of a second wall unit align to form a generallycircular opening between the first and second wall units. A gasket 8402may be positioned within the circular opening to provide a secureinterconnection between the first and second wall units.

Wall unit 10 is typically part of an overall wall system 21 as shown inFIGS. 88-90. A bottom end of embedded metal studs 14 and 16 are seatedin and attached to a bottom track 44 and a top track 42. Thisconfiguration leads to the formation of bottom channel 52 and topchannel 54. Channels 52 and 54 can be filled with correspondingly shapedexpanded polymer material, or alternatively with a molding shaped to fitin channels 52 or 54.

In various embodiments, the top track 42 may comprise slotted track suchas that slotted track disclosed in U.S. Pat. No. 5,127,760, thedisclosure of which is herein incorporated by reference in its entirety.The portions of the top track 42 and the bottom track 44 extendingbetween the studs 14, 16 can be filled with correspondingly shapedexpanded polymer material, or alternatively with a molding shaped to fitin those sections of tracks 42, 44.

As a non-limiting example molding 58 can be inserted into top channel 54and attached to top track 42 by inserting fasteners 60 into holes 62 intop track 42 as shown in FIG. 92. Molding 58 provides a thermal break tothe exposed metal track 42. In various embodiments, both sides of eachof the embedded metal studs 14 and 16 are exposed at the ends of thepanels. This feature overcomes a basic structural problem in the priorart by providing a positive mechanical connection to both sides of theembedded metal studs when top track 42 and bottom track 44 areinstalled. Further, when slotted top tracks are employed, the combinedcomposite building panels can move relative to the top track 42 when thepanels are attached to the top track 42 by mechanical fastenersextending through the slots therein.

Wall system 21 is shown in FIGS. 88-91, in which three wall units areconnected. Where the ends of two wall units meet to form a corner, anoutside corner attachment 47 secures the ends of the two wall unitstogether. The outside corner attachment may be either an interior cornerpost assembly 9800 or an exterior corner post assembly 9900. Referringnow to FIGS. 94-99, an interior corner post assembly 9800 includes aninterior corner post 9802, a first corner stud 9804, a second cornerstud 9806 and a plurality of fastening members 9807 for securing thefirst corner stud 9804 to the interior corner post 9802 and the secondcorner stud 9806.

Interior corner post 9802 comprises a body 9808 with a length 9810 and awidth 9812. The body 9808 comprises a web 9814 with a first end 9816 anda second end 9818, a first flange 9820 extending generallyperpendicularly from the second end 9818 of the web 9814, and a secondflange 9822 extending generally perpendicularly from a central portionbetween the first end 9816 and the second end 9818 of the web 9814 in adirection opposite to the first flange 9820. First flange 9820 maycomprise a plurality of holes 9824 extending longitudinally along alength of the body 9808. The holes 9824 allow fastening members 9807 tobe inserted therethrough to secure the first corner stud 9804 to theinterior corner post 9802.

First corner stud and second corner stud, denoted generally as 9804 and9806, respectively, each comprises a body 9826 having a length and awidth. In various embodiments, the first and second corner studs 9804,9806 may comprise those studs manufactured by Dietrich Industries, Inc.of Pittsburgh, Pa. under the trademark HDS™. As shown in FIGS. 97 and98, the body 9826 comprises a web 9828 having a first end 9830 and asecond end 9832, a first flange 9834 extending generally perpendicularlyfrom the first end 9830 of the web 9828, a return lip 9836 extendinggenerally perpendicularly from the first flange 9834 and in a directiongenerally away from the first end 9830 of the web 9828, and a secondflange 9838 extending generally perpendicularly from the return lip 9836and towards the web 9828.

The body 9826 also comprises a third flange 9840 extending generallyperpendicularly from the second end 9832 of the web 9828, a return lip9842 extending generally perpendicularly from the third flange 9840 andin a direction generally away from the second end 9832 of the web 9828,and a fourth flange 9844 extending generally perpendicularly from thereturn lip 9842 and towards the web 9828.

As shown in FIG. 98, interior corner post assembly 9800 is constructedby providing an interior corner post 9802, a first corner stud 9804 anda second corner stud 9806. The web 9828 of the first corner stud 9804 ispositioned adjacent to the first flange 9820 of the interior corner post9802 and attached thereto using one or more fastening members 9807. Afirst channel, indicated generally as 9846, for receiving a wall unit 10is thereby formed by a portion of the web 9828 of the first corner stud9804, the second flange 9822 of the interior corner post 9802 and theweb 9814 of the interior corner post 9802. The web 9828 of the secondcorner stud 9806 is positioned adjacent to the third flange 9840 of thefirst corner stud 9804 and secured thereto using a fastening member9807. A second channel, indicated generally as 9848, for receiving asecond wall unit 10′ is thereby formed by a portion of the web 9828 ofthe second corner stud 9806, a portion of the web 9828 of the firstcorner stud 9804 and the web 9814 of the interior corner post 9802.First wall unit 10 and second wall unit 10′ are positioned in firstchannel 9846 and second channel 9848, respectively, such that theexposed end of embedded studs are positioned parallel to the firstcorner stud 9804 and the second corner stud 9806. A finish surface 475,such as dry wall, can then be secured to the exposed ends of theembedded studs, the first corner stud 9804 and the second corner stud9806 using a suitable fastening member.

The fastening member 9807 is any suitable fastener including, but notlimited to, screws, nails, pins or the like.

In an embodiment of the invention, corner attachment 47 can be a cornerpost assembly as shown in FIGS. 100-106, where an exterior corner postassembly, indicated generally as 9900, includes an exterior corner post9902, a first corner stud 9904, a second corner stud 9906 and aplurality of fastening members 9907 for securing the first corner stud9904 to the exterior corner post 9902 and the second corner stud 9906.In various embodiments, the first and second corner studs 9904, 9906 maycomprise those studs manufactured by Dietrich Industries, Inc. ofPittsburgh, Pa. under the trademark HDS™.

The exterior corner post 9902 comprises a body 9908 with a length 9910and a width 9912. The body 9908 comprises a web 9914 with a first end9916 and a second end 9918, a first flange 9920 extending generallyperpendicularly from the second end 9918 of the web 9914, and a lipportion 9922 extending generally perpendicularly from the first flange9920. The body 9908 also includes right-angled tabs 9924 positionedalong the length 9910 of the body 9908. The number of tabs 9924 can varyas needed provide structural integrity. For example, as shown in FIG.100, eight tabs 9924 can be used. However, it will be understood thatother quantities, sizes and shaped tabs 9924 may be employed.

First corner stud, denoted generally as 9904, comprises a body 9926having a length and a width. The body 9926 comprises a web 9928 having afirst end 9930 and a second end 9932, a first flange 9934 extendinggenerally perpendicularly from the first end 9930 of the web 9928, areturn lip 9936 extending generally perpendicularly from the firstflange 9934 and in a direction generally away from the first end 9930 ofthe web 9928, and a second flange 9938 extending generallyperpendicularly from the return lip 9836 and towards the web 9928.

The body 9926 also comprises a third flange 9940 extending generallyperpendicularly from the second end 9932 of the web 9928, a return lip9942 extending generally perpendicularly from the third flange 9940 andin a direction generally away from the second end 9932 of the web 9928,and a fourth flange 9944 extending generally perpendicularly from thereturn lip 9942 and towards the web 9928.

The second corner stud, denoted generally as 9906, comprises a body 9946having a length and a width. The body 9946 comprises a web 9948 having afirst end 9950 and a second end 9952, a first flange 9954 extendinggenerally perpendicularly from the first end 9950 of the web 9948, afirst return lip 9956 extending generally perpendicularly from the firstflange 9954 and in a direction generally away from the first end 9950 ofthe web 9948.

The body 9946 also comprises a second flange 9958 extending generallyperpendicularly from the second end 9952 of the web 9948 and a secondreturn lip 9960 extending generally perpendicularly from the secondflange 9958 and in a direction generally away from the second end 9952of the web 9948.

The exterior corner post assembly 9900 may be constructed by providingan exterior corner post 9902, a first corner stud 9904 and a secondcorner stud 9906. The web 9928 of the first corner stud 9904 is thenpositioned adjacent to the web 9914 of the exterior corner post 9902 andattached thereto using a fastening member 9907. The web 9948 of thesecond corner stud 9906 is positioned adjacent to the return lip 9936 ofthe first corner stud 9904 and secured thereto using a fastening member9907. A first channel 9960 for receiving a wall unit 10 is formed by thelip portion 9922, the first flange 9820 and the web 9914 of the exteriorcorner post 9902. A second channel 9862 for receiving a second wall unit10′ is formed by a portion of the web 9914 of the exterior corner post9902, the tab 9924 of the exterior corner post 9902, the first flange9954 of the second corner stud 9906 and the first flange 9934 of thefirst corner stud 9904. First wall unit 10 and second wall unit 10′ arepositioned in first channel 9960 and second channel 9962, respectively,such that the exposed end of embedded studs are positioned parallel tothe first corner stud 9904 and the second corner stud 9906. A finishsurface 475, such as dry wall, can then be secured to the exposed endsof the embedded studs, the first corner stud 9904 and the second cornerstud 9906 using a suitable fastening member to form an inside wall.

The fastening member 9807 is any suitable fastener including, but notlimited to, screws, nails, pins or the like.

Also, additional metal studs 49 can be included to add strength to theformed corners. Thus the wall system includes interconnecting bottom 44and top 42 tracks that may be of the type and construction describedabove and embedded metal studs 51 secured together at corner attachmentunits that extend along the height of each wall unit.

Openings for windows and doors are provided by framing the ends of theopening with two or more embedded metal studs placed adjacent to eachother (shown as 53). Upper member 55 and lower member 57 are connectedto the embedded metal studs to form a framed opening. The openings canbe adapted to readily accept pre-manufactured windows and doors.

The strength and integrity of wall system 21 can be enhanced byincluding spacer bars 61 that are arranged to pass through openings,such as utility holes 46 in embedded metal studs 14 and 16. Referringnow to FIGS. 107 and 108, spacer bars 61 are attached to embedded metalstuds 14 and 16 and are arranged, as shown, in a generally perpendicularrelationship to metal studs 14 and 16, although spacer bars 61 can bearranged to form any suitable angle with embedded metal studs 14 and 16that enhances the strength and integrity or wall system 21. Spacer barsand metal studs that can be incorporated in the invention include thoseavailable under the trademarks TRADE READY® SPAZZER® available fromDietrich Industries, Inc., Pittsburgh, Pa. as well as those disclosed inU.S. Pat. Nos. 5,784,850, 6,021,618 and 6,708,460, the relevant portionsof which are herein incorporated by reference. In one embodiment,SPAZZER® bar Model No. 5400 is used. Retainer clips such as SPAZZER® BARGUARD™ retainer clips, also available from Dietrich Industries, Inc.,can be used for load bearing applications, if desired.

The various metal structural parts in wall system 21 can be secured orattached to one another by way of welds 71 and/or screws 73. It isconceivable, however, that other forms of mechanical fasteners may alsobe employed without departing form the spirit and scope of the presentinvention.

Some advantages of the present wall units and wall systems include theability to easily run utilities prior to attaching a finish surface tothe exposed ends of the embedded metal studs. The exposed metal studsfacilitate field structural framing changes and additions and leave thestructural portions of the assembly exposed for local building officialsto inspect the framing.

Referring to FIG. 109, in an embodiment of the invention, wall unit 10includes expanded polymer body 12 (central body), right facing embeddedmetal studs 16, which include flanges 11 and have utility holes 46located in an exposed portion of embedded studs 16, expansion holes 13in an embedded portion (thermal portion) of embedded studs 16 andembedded end 22, which does not touch outer surface 24 of expandedpolymer body 12. The embedded metal studs 16 also have exposed end 28(structural portion) respectively that extends from inner surface 30 ofexpanded polymer body 12. While C-type embedded studs are illustrated inFIG. 109, this is not to be construed as limiting the present inventionas the use of other types of studs, such as CC-type embedded studs andCT-type embedded studs, may be successfully employed in similar manners.

A utility space defined by inner surface 30 of expanded polymer body 12and flanges 11 adapted for running utilities is provided. Flanges 11 mayhave a finish surface or material attached to them, a side of whichfurther defines the utility space.

In an embodiment of the invention, the utility space may be adapted anddimensioned to receive a variety of commercially available standardand/or pre-manufactured components, such as windows, doors and medicinecabinets as well as customized cabinets, shelving, etc.

In an embodiment of the invention, utility holes 46 may be adapted toallow utilities (as shown, electrical line 15) to be installed in atransverse direction through embedded studs 16.

The utilities can be one or more selected from water lines (eitherpotable, or as a non-limiting example hot water lines for radiantheating), waste lines, chases, telephone lines, cable television lines,computer lines, fiber optic cables, satellite dish communication lines,antenna lines, electrical lines, ductwork, gas lines, etc.

In a particular embodiment of the invention, wall unit 10 is attached tobottom track 44. In this embodiment, bottom track 44 is adapted to holda volume at least equivalent to the volume of the expanded polymermatrix in expanded polymer body 12, in liquid or molten form. In someinstances, this volume can be defined by bottom 101 and sides 103 ofbottom track 44 and the portions of embedded bars 16 within the spacedefined by bottom track 44.

Non-limiting examples of suitable finish surfaces include wood, rigidplastics, wood paneling, concrete panels, cement panels, drywall,sheetrock, particle board, rigid plastic panels, a metal lath, or anyother suitable material having decorating and/or structural functions.

Further, the air space between the inner surface of the expanded polymerbody and the finish surface allows for improved air circulation, whichcan minimize or prevent mildew. Additionally, because the metal studsare not in direct contact with the outer surface, thermal bridging viathe highly conductive embedded metal studs is avoided and insulationproperties are improved.

The present invention also provides composite building panels useful forfloor units and floor systems. As shown in FIG. 110, floor unit 90includes expandable polymer panel 92 (central body) and embedded metaljoists 94 and 96 (embedded framing studs). Expandable polymer panel 92includes openings 98 that traverse all or part of the length of expandedpolymer panel 92 (as described regarding openings 18 in expanded polymerbody 12). The embedded metal joists 94 and 96 have embedded ends 104 and106, respectively, that are in contact with top surface 102 of expandedpolymer panel 92. The embedded metal joists 94 and 96 also have exposedends 108 and 110, respectively, that extend from bottom surface 100 ofexpanded polymer panel 92.

Embedded metal joists 94 and 96 include first transverse members 124 and126, respectively, extending from embedded ends 104 and 106,respectively, which are generally in contact with top surface 102 andexposed ends 108 and 110 include second transverse members 128 and 129,respectively, which extending from exposed ends 108 and 110,respectively. The space defined by bottom surface 100 of expandedpolymer panel 92 and the exposed ends 108 and 110 and second transversemembers 128 and 129 of embedded metal joists 94 and 96 can be orientedto accept ductwork or other members placed between embedded metal joists94 and 96 adjacent bottom surface 100.

Expanded polymer panel 92 can have a thickness, measured as the distancefrom top surface 102 to bottom surface 100 similar in dimensions to thatdescribed above regarding expanded polymer body 12. See FIG. 110.

Exposed ends 108 and 110 extend at least 1, in some cases at least 2,and in other cases at least 1.18 inches (3 cm) away from bottom surface100 of expanded polymer panel 92. Also, exposed ends 108 and 110 canextend up to 60, in some cases up to 40, and in other cases up to 7.87in (20 cm) away from bottom surface 100 of expanded polymer panel 92.Exposed ends 108 and 110 can extend any of the distances or can rangebetween any of the distances recited above from bottom surface 100.

In an embodiment of the invention, embedded metal joists 94 and 96 havea cross-sectional shape that includes embedding lengths 114 and 116,embedded ends 104 and 106, and exposed ends 108 and 110. The orientationof embedded metal joists 94 and 96 is referenced by the direction ofopen ends 118 and 120. In an embodiment of the invention, open ends 118and 120 are oriented toward each other. In this embodiment, floor unit90 is adapted to accept ductwork. As a non-limiting example, a HVAC ductcan be installed along the length of embedded metal joists 94 and 96.

As used herein, the term “ductwork” refers to any tube, pipe, channel orother enclosure through which air can flow from a source to a receivingspace; non-limiting examples being air flowing from heating and/orair-conditioning equipment to a room, make-up air flowing from a room toheating and/or air-conditioning equipment, fresh air flowing to anenclosed space, and/or waste air flowing from an enclosed space to alocation outside of the enclosed space. In some embodiments, ductworkincludes generally rectangular metal tubes that are located below andextend generally adjacent to a floor.

The spacing between each of embedded metal joists 94 and 96 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

Openings 98 can have various cross-sectional shapes and similar spacingand cross-sectional area as described regarding openings 18 in expandedpolymer body 12.

As shown in FIG. 110, expanded polymer panel 92 can extend for adistance with alternating embedded metal joists 94 and 96 placedtherein. The length of floor unit 90 can be any length that allows forsafe handling and minimal damage to floor unit 90 as described regardingthe length of wall unit 10. In some embodiments, an end of floor unit 90can be terminated with an embedded metal joist.

As shown in FIG. 110, expanded polymer panel 12 has a finite length andhas a male terminal end 91 that includes forward edge 93 and trailingedge 95 and a receiving end 97 which includes recessed section 99 andextended section 101, which is adapted to receive forward edge 93, andtrailing edge 95. Typically, lengths of floor units 90 areinterconnected by inserting a forward edge 93 from a first floor unit 90into a recessed section 99 from a second floor unit 90. In this manner,a larger floor section containing any number of floor units can beassembled and/or arrayed.

The width of floor unit 90 can be any width that allows for safehandling and minimal damage to floor unit 90. The width of floor unit 90may be determined by the length of embedded metal joists 94 and 96. Thewidth of floor unit 90 can be at least 1 and in some cases at least 4.92feet (1.5 m) and can be up to 9.84 feet (3 m) and in some cases up to8.20 feet (2.5 m). In some instances, in order to add stability to floorunit 90, reinforcing cross-members (not shown) can be attached toembedded metal joists 94 and 96. The width of floor unit 90 can be anyvalue or can range between any of the values recited above.

Floor unit 90 may comprise a typically part of an overall floor system,which may include, for example, a plurality of composite floor panels asdescribed herein, ductwork attached to the reinforcing members of atleast one floor panel, and a flooring material attached to one or moreof the first transverse members of the composite floor panels.

The floor panels interconnect with the male ends, which include aforward edge or tongue edge, and the female ends, which include a grooveor recessed section, arrayed such that the tongue (male) and/or groove(female) of each panel is in sufficient contact with a correspondingtongue and/or groove of another panel to form a structure having aplanar surface.

In the present floor system, ductwork can be attached to the reinforcingmembers of at least one composite floor panel.

Additionally, a flooring material can be attached to one or more of thefirst transverse members of the composite floor panels. Any suitableflooring material can be used in the invention. Suitable flooringmaterials are materials that can be attached to the transverse membersand cover at least a portion of the expanded polymer panel. Suitableflooring materials may include, but are not limited to, plywood, woodplanks, tongue and grooved wood floor sections, sheet metal, sheets ofstructural plastics, stone, ceramic, cement, concrete, and combinationsthereof.

Generally, the floor system forms a plane that extends laterally from afoundation and/or a structural wall.

FIGS. 126A and 126B show floor system components 140 and 141respectively. As shown in FIGS. 126A and 126B, the floor system isestablished by contacting forward edge 93 with recessed section 99 toform a continuous floor 142. Like features of the individual floorpanels are labeled as indicated above. As described above, variousshaped types of ductwork can be secured in the space defined by bottomsurface 100 of expanded polymer panel 92 and the exposed ends 108 and110 and second transverse members 128 and 129 of embedded metal joists94 and 96. As non-limiting examples, rectangular ventilation duct 147 isshown in FIG. 126A and oval air duct 148 is shown in FIG. 126B.

The composite building panels, wall units, floor units, tilt upinsulated panels and I-beam panels described herein contain variationsthat are not meant as limitations. Any of the variations discussed inone embodiment can be used in another embodiment without limitation.

The embodiments of the invention shown in FIGS. 126A and 126B show anon-limiting example of combinations of the composite panels describedherein combining features of the various panels. This embodimentcombines I-beam panel 140 and floor panel 90 (shown as 92 and 92A). Inthis embodiment, receiving end 176 of I-beam panel 140 accepts forwardedge 93 of floor panel 92 and recessed section 99 of floor panel 92Aaccepts forward edge 172 of I-beam panel 140 to provide tongue andgroove connections to establish continuous floor system 141. In thisembodiment, circular ductwork 148 is installed along bottom surface 100of floor panel 92 between embedded metal joists 94 and 96. In thisembodiment, the flooring material is concrete layer 145, which coverstop surface 102 of floor panels 92 and 92A and outer face 162 of I-beampanel 140. I-beam channel 182 extends from and is open to outer face 162and is filled with concrete and the thickness of concrete layer 145 issufficient to encase exposed ends 158 and 160 of I-beam panel 140. Thecombination shown in this embodiment provides an insulated concretefloor system where utilities can be run under an insulation layer.

As shown in FIG. 112, an end of embedded metal joists 94 and 96 areseated in and attached to a joist rim 122 and a second joist rim isattached to the other end of embedded metal joists 94 and 96. A floorbase 149, typically plywood, particle board or other supporting surfaceor flooring material, can be attached to the exposed ends 108 and 110.Alternatively, floor base 149 can be attached to embedded ends 104 and106.

Referring now to FIGS. 114 and 115, a first wall unit 10 with a firstend and a second end is positioned with the first end adjacent to asurface and the second end positioned in a level track 128. A joist rim122 of a floor system is fixedly connected to the level track 128. Invarious embodiments, the joist rims manufactured by Dietrich Industriesof Pittsburgh, Pa. under the trademark TRADE READY® may be employed. Aplurality of metal joists 94 are attached to the joist rim 122 andsupport a floor base 149. A bottom track 44 is also provided inconnection with joist rim 122 opposite to level track 128. A second wallunit 10′ with a first end and a second is positioned with the first endin the bottom track 44. When the first and second wall units 10, 10′ areconstructed in this manner, a gap 117 between the expanded polymer body12 of the first wall unit 10 and the expanded polymer body 12′ of thesecond wall unit is created. This gap 117 can be filled with anysuitable material 115, such as insulation. The material 115 may besecured to the structure using an adhesive, nails, screws or any othersuitable securing method.

In this manner, a multi-story structure can be constructed using thebuilding panels of the present invention.

Referring back to FIG. 112, embedded metal joists 94 and 96 have utilityholes 127 spaced along their length. Utility holes 127 are useful forrunning wiring for electricity, telephone, cable television, speakers,and other electronic devices. Utility holes 127 can have variouscross-sectional shapes, non-limiting examples being round, oval,elliptical, square, rectangular, triangular, hexagonal or octagonal. Thecross-sectional area of Utility holes 127 can also vary independentlyone from another or they can be uniform. The cross-sectional area ofutility holes 127 is limited by the dimensions of embedded metal joists94 and 96, as utility holes 127 will fit within their dimensions and notsignificantly detract from their structural integrity and strength.

Expansion holes 13, as mentioned above are useful in that as expandedpolymer body 92 is molded, the polymer matrix expands through expansionholes 113 and the expanding polymer fuses. This allows the polymermatrix to encase and hold embedded studs 94 and 96 by way of the fusionin the expanding polymer. In an embodiment of the invention, expansionholes 13 can have a flanged and in many cases a rolled flange surface toprovided added strength to the embedded metal studs.

In an embodiment of the invention, the floor system can be placed on afoundation. However, because foundations are rarely perfectly level, alevel track 128 can be attached to foundation 130 prior to placement ofthe floor system (see FIGS. 112 and 113). Level track 128 can be placedon foundation 128 and leveled utilizing conventional techniques. Thelevel is made permanent by fastening level track 128 to foundation 130by using fasteners 131 (nails shown, although screws or other suitabledevices can be used) via fastening holes 132. Screws 133 can also beused to attach level track 128 to foundation 130 via screw holes 135.Screws 133 can also maintain the level position of level track 128 untila more permanent positioning is achieved. Alternatively or additionallymortar can be applied via mortar holes 134 to fill the space betweenlevel track 128 and the top of foundation 130. After level track 128 hasbeen attached and/or the mortar has sufficiently set, the flooringsystem can be fastened to the foundation.

In various embodiments, level track 128 includes side rails 137, whichare adapted to extend over a portion of foundation 130. The width oflevel track 128 is the transverse distance of a top portion of leveltrack 128 from one side rail 137 to the other. The width of level track128 is typically slightly larger than the width of foundation 130. Thewidth of level track 128 can be at least 3.94 inches (10 cm), in somecases at least 5.90 inches (15 cm), in other cases at least 7.87 in (20cm) and in some instances at least 8.27 in (21 cm). Also, the width oflevel track 128 can be up to 15.748 in (40 cm), in some cases up to13.78 in (35 cm), and in other cases up to 11.81 in (30 cm). The widthof level track 128 can be any value or range between any of the valuesrecited above.

The length of side rail 137 is the distance it extends from the topportion of level track 128 and is sufficient in length to allow forproper leveling of level track 128 and attachment to foundation 130 130via fasteners 131 and fastening holes 132. The length of side rail 137can be at least 1.58 inches (4 cm), in some cases at least 1.97 inches(5 cm), and in other cases at least 2.76 inches (7 cm). Also, the lengthof side rail 137 can be up to 7.87 in (20 cm), in some cases up to 5.90inches (15 cm), and in other cases up to 4.72 inches (12 cm). The lengthof side rail 137 can be any value or range between any of the valuesrecited above.

An embodiment of the invention relates to a floor or tilt up insulatedpanel that is adapted to act as a concrete I-beam form. As shown in FIG.111, I-beam panel 140 includes expanded polymer form 142 (central body)and embedded metal members 144 and 146 (embedded reinforcing bars).Expanded polymer form 142 includes openings 148 that traverse all orpart of the length of expanded polymer form 142. The embedded metalmembers 144 and 146 have embedded ends 152 and 156 respectively that arein contact with inner face 150 of expanded polymer form 142. Theembedded metal members 144 and 146 also have exposed ends 158 and 160,respectively, that extend from outer face 162 of expanded polymer form142.

Expanded polymer form 142 can have a thickness, measured as the distancefrom inner face 150 to outer face 162 of at least 8, in some cases atleast 10, and in other cases at least 4.72 inches (12 cm) and can be upto 100, in some cases up to 75, and in other cases up to 1.97 ft (60cm). The thickness of expanded polymer form 142 can be any distance orcan range between any of the distances recited above.

Exposed ends 158 and 160 extend at least 1, in some cases at least 2,and in other cases at least 1.18 inches (3 cm) away from outer face 162of expanded polymer form 142. Also, exposed ends 158 and 160 can extendup to 60, in some cases up to 40, and in other cases up to 7.87 in (20cm) away from outer face 162 of expanded polymer form 142. Exposed ends158 and 160 can extend any of the distances or can range between any ofthe distances recited above from outer face 100.

In an embodiment of the invention, embedded metal members 144 and 146have a cross-sectional shape that includes embedding lengths 164 and166, embedded ends 152 and 156, and exposed ends 158 and 160. Theorientation of embedded metal members 144 and 146 is referenced by thedirection of open ends 168 and 170. In an embodiment of the invention,open ends 168 and 170 are oriented toward each other. In thisembodiment, I-beam panel 140 is adapted to be embedded in the concretethat is applied to outer face 162.

The spacing between each of embedded metal members 144 and 146 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

Openings 148 can have various cross-sectional shapes and similar spacingand cross-sectional area as described regarding openings 18 in expandedpolymer body 12.

As shown in FIG. 111, expanded polymer panel 140 has a finite length andhas a male terminal end 170 that includes forward edge 172 and trailingedge 174 and a receiving end 176 which includes recessed section 178,which is adapted to receive forward edge 172, and protruding edge 180.Typically, lengths of I-beam panels 140 are interconnected by insertinga forward edge 172 from a first I-beam panel 140 into a recessed section178 of a second I-beam panel. In this manner, a larger roof or wallsection containing any number of I-beam panels can be assembled and/orarrayed. The width of I-beam panel 140, measured as the distance fromprotruding edge 180 to trailing edge 174 can typically be at least 20,in some cases at least 30, and in other cases at least 13.78 in (35 cm)and can be up to 150, in some cases up to 135, and in other cases up to4.10 ft (125 cm). The width of I-beam panel 140 can be any value or canrange between any of the values recited above.

As can also be seen in FIG. 111, I-beam panel 140 includes I-beamchannel 182. Various forms of the present I-beam panel are advantageouswhen compared to prior art systems in that the connection betweenadjacent panels in the prior art is provided along the thin section ofexpanded polymer below I-beam channel 182. The resulting thin edge ofthose prior panels is prone to damage and/or breakage during shipmentand handling. The I-beam panel of the present invention eliminates thisproblem by providing a connection between adjacent panels at ends 170and 176. Therefore, when the I-beam channel 182 is molded with concreteor the like, damage resulting from the concrete seeping through a gapcreated by the connection is eliminated.

In an embodiment of the invention, rebar or other concrete reinforcingrods can be placed in I-beam channel 182 in order to strengthen andreinforce a concrete I-beam formed within I-beam channel 182.

In another embodiment of the invention shown in FIG. 116, instead ofI-beam channel 182, I-beam panel 141 includes channel 183. Channel 183is adapted to accept ductwork or other mechanical and utility parts,devices and members.

An example of an I-beam system 200 according to various embodiments ofthe present invention is shown in FIG. 117, where four I-beam panels 140are connected by inserting a forward edge 172 from a first I-beam panel140 into a recessed section 178 of a second I-beam panel. Concrete ispoured, finished and set to form a concrete layer 202 that includesconcrete I-beams 204, which are formed in I-beam channels 182. Theembodiment shown in FIG. 117 is an alternating embodiment, where thedirection of I-beam channel 182 of each I-beam panel 140 alternatelyfaces toward concrete layer 202 and includes concrete I-beam 204 orfaces away from concrete layer 202 and I-beam channel 182 does notcontain concrete. In an embodiment of the invention, the facing awayI-beam panel can be I-beam panel 141. Alternatively, every I-beam panel140 could face concrete layer 202 and include concrete I-beam 204.

In the embodiment shown in FIG. 117, exposed ends 158 and 160 are eitherembedded in concrete layer 202 or are exposed. The exposed ends 158 and160 are available as attachment points for a finish surface such aswood, rigid plastics, wood paneling, concrete panels, cement panels,drywall, sheetrock, particle board, rigid plastic panels, or any othersuitable material having decorating and/or structural functions or otherconstruction substrates 210. The attachment is typically accomplishedthrough the use of screws or other suitable fastener arrangements.

In various embodiments of the invention, I-beam system 200 is assembledon a flat surface and a first end is lifted while a second end remainsstationary resulting in orienting I-beam system 200 generallyperpendicular to the flat surface. This is often referred to as “tiltinga wall” in the art and in this embodiment of the invention, I-beamsystem 200 is referred to as a “tilt-wall.”

In another embodiment of the invention, I-beam system 200 can be used asa roof on a structure.

An embodiment of the invention relates to a tilt up insulated panel thatis adapted for use as a wall or ceiling panel. As shown in FIGS.118-121, one-sided wall panel 340 includes a reinforced body 341 thatincludes expanded polymer form 342 (central body) and embedded metalmembers 344 and 346 (embedded reinforcing bars). Expanded polymer form342 can include openings 348 and utility chases 349, which traverse allor part of the length of expanded polymer form 342. The embedded metalmembers 344 and 346 have embedded ends 352 and 356, respectively, thatare not in contact with inner face 350 of expanded polymer form 342. Theembedded metal members 344 and 346 also have exposed ends 358 and 360,respectively, that extend from outer face 362 of expanded polymer form342.

Expanded polymer form 342 can have a thickness similar to that describedregarding expanded polymer form 142. Exposed ends 358 and 360 extend atleast 0.39 in (1 cm), in some cases at least 0.79 inches (2 cm), and inother cases at least 1.18 inches (3 cm) away from outer face 362 ofexpanded polymer form 342. Also, Exposed ends 358 and 360 can extend upto 2.36 in (60 cm), in some cases up to 15.748 in (40 cm), and in othercases up to 7.87 in (20 cm) away from outer face 362 of expanded polymerform 342. Exposed ends 358 and 360 can extend any of the distances orcan range between any of the distances recited above from outer face362.

In an embodiment of the invention, embedded metal members 344 and 346have a cross-sectional shape that includes embedding lengths 364 and366, embedded ends 352 and 356, and exposed ends 358 and 360. Theorientation of embedded metal members 344 and 346 is referenced by thedirection of embedded ends 352 and 356. In a particular embodiment ofthe invention, embedded ends 352 and 356 are oriented away from eachother. In this embodiment, one-sided wall panel 340 is adapted so thatexposed ends 358 and 360 of embedded metal members 344 and 346 areembedded in concrete 370 that is applied to outer face 362.

The spacing between each of embedded metal members 344 and 346 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

Referring now to FIGS. 118 and 120, in an embodiment of the invention,one-sided wall panel 340 includes expanded polymer body 342 (centralbody), embedded metal members 344 and 346 (embedded framing studs),which include flanges 311, cornered ends 312, utility holes 346 locatedin an exposed portion of embedded metal members 344 and 346, expansionholes 313 in an embedded portion of embedded metal members 344 and 346,and embedded ends 344 and 346, which do not touch inner face 350.

In an embodiment of the invention, inner face 350 can have a corrugatedsurface, which can be molded in or cut in, which enhances air flowbetween inner face 350 and any surface attached thereto.

With continuing reference to FIGS. 118 and 120, expansion holes 313 areuseful in that as expanded polymer body 342 is molded, the polymermatrix expands through expansion holes 313 and the expanding polymerfuses. This allows the polymer matrix to encase and hold embedded metalmembers 344 and 346 by way of fusion in the expanding polymer. In anembodiment of the invention, expansion holes 313 can have a flanged andin many cases a rolled flange surface to provided added strength to theembedded metal members.

Openings 348 can have various cross-sectional shapes and similar spacingand cross-sectional area as described regarding openings 18 in expandedpolymer body 12.

Referring now to FIGS. 118 and 119, reinforced body 341 has a finitelength and has a male terminal end 371 that includes forward edge 372and a receiving end 376 which includes recessed section 376, which isadapted to receive forward edge 372. Typically, lengths of one-sidedwall panel 340 are interconnected by inserting a forward edge 372 from afirst one-sided wall panel 340 into a recessed section 378 of a secondone-sided wall panel. In this manner, a larger wall or ceiling sectioncontaining any number of one-sided wall panels can be assembled and/orarrayed. The width of one-sided wall panel 340, measured as the distancefrom protruding edge 380 to trailing edge 374 can typically be at least20, in some cases at least 30, and in other cases at least 13.78 in (35cm) and can be up to 150, in some cases up to 135, and in other cases upto 4.10 ft (125 cm). The width of one-sided wall panel 340 can be anyvalue or can range between any of the values recited above.

An example of a one-sided wall panel 340 according to variousembodiments of the present invention is shown in FIG. 118, where fourembedded metal members 344 and 346 are used. Concrete is poured,finished and set to form a concrete layer 370 that encases exposed ends358 and 360 of embedded metal members 344 and 346.

The embedded ends 350 and 356 of embedded metal members 344 and 346 areavailable as attachment points for a finish surface such as wood, rigidplastics, wood paneling, concrete panels, cement panels, drywall,sheetrock, particle board, rigid plastic panels, or any other suitablematerial having decorating and/or structural functions or otherconstruction substrates sheetrock 375 as shown in FIG. 118. Theattachment is typically accomplished through the use of screws or othersuitable fastener arrangements.

Another embodiment of the invention is shown in FIG. 121. In thisembodiment, reinforcement mesh 371 is attached to exposed ends 358 and360 of embedded metal members 344 and 346. Reinforcement mesh 371 can bemade of any suitable material, non-limiting examples being fiberglass,metals such as steel, stainless steel and aluminum, plastics, syntheticfibers and combinations thereof. Desirably, after reinforcement mesh 371is attached to exposed ends 358 and 360, concrete layer 370 is poured,finished and set so as to encase reinforcement mesh 371 and exposed ends358 and 360. In this embodiment, reinforcement mesh 371 increases thestrength of concrete layer 370 as well as increasing the strength of theattachment of concrete layer 370 to reinforced body 341.

In an embodiment of the invention, one-sided wall panel 340 is assembledon a flat surface and a first end is lifted while a second end remainsstationary resulting in orienting one-sided wall panel 340 generallyperpendicular to the flat surface. This is often referred to as “tiltinga wall” in the art and in this embodiment of the invention, one-sidedwall panel 340 is referred to as a “tilt-up wall.”

An embodiment of the invention relates to another tilt up insulatedpanel that is adapted for use as a wall or ceiling panel. As shown inFIGS. 122-125, two-sided wall panel 440 includes a reinforced body 441that includes expanded polymer form 442 (central body) and embeddedmetal members 444 and 446 (embedded reinforcing bars). Expanded polymerform 442 can include openings 448 that traverse all or part of thelength of expanded polymer form 442. The embedded metal members 444 and446 have a first exposed end 452 and second exposed end 456 respectivelythat extend from first face 462 of expanded polymer form 442. Theembedded metal members 444 and 446 also have second exposed ends 458 and460 respectively that extend from second face 450 of expanded polymerform 442.

Expanded polymer form 442 can have a thickness, measured as the distancefrom second face 450 to first face 462 similar to that describedregarding expanded polymer form 142.

The exposed ends can extend at least 1, in some cases at least 2, and inother cases at least 1.18 inches (3 cm) away either face 450 or face 462of expanded polymer form 442. Also, the exposed ends can extend up to60, in some cases up to 40, and in other cases up to 7.87 in (20 cm)away from either face of expanded polymer form 442. The exposed ends canextend any of the distances or can range between any of the distancesrecited above from either face of expanded polymer form 442.

In an embodiment of the invention, exposed ends 452, 456, 458, and 460are embedded in first concrete layer 469 and second concrete layer 470that are applied to faces 450 and 462.

The spacing between each of embedded metal members 444 and 446 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

In an embodiment of the invention, two-sided wall panel 440 includesexpanded polymer body 442 (central body), embedded metal members 444 and446 (embedded framing studs), which cornered ends 412, utility holes 446located in an exposed portion of embedded metal members 444 and 446, andexpansion holes 413 in an embedded portion of embedded metal members 444and 446.

Expansion holes 413 are useful in that, as expanded polymer body 442 ismolded, the polymer matrix expands through expansion holes 413 and theexpanding polymer fuses. This allows the polymer matrix to encase andhold embedded metal members 444 and 446 by way of fusion in theexpanding polymer. In an embodiment of the invention, expansion holes413 can have a flanged portion around their respective perimeters and inmany cases a rolled flange surface to reinforce the area around theholes.

Openings 448 can have various cross-sectional shapes and similar spacingand cross-sectional area as described regarding openings 18 in expandedpolymer body 12.

Reinforced body 441 has a finite length and has a male terminal end 471that includes forward edge 472 and a receiving end 476 which includesrecessed section 478, which is adapted to receive forward edge 472.Typically, lengths of two-sided wall panel 440 are interconnected byinserting a forward edge 472 from a first two-sided wall panel 440 intoa recessed section 478 of a second two-sided wall panel. In this manner,a larger wall or ceiling section containing any number of two-sided wallpanels can be assembled and/or arrayed. The width of one-sided wallpanel 440, measured as the distance from forward edge 472 to recessedsection 478 can typically be at least 20, in some cases at least 30, andin other cases at least 13.78 in (35 cm) and can be up to 150, in somecases up to 135, and in other cases up to 4.10 ft (125 cm). The width oftwo-sided wall panel 440 can be any value or can range between any ofthe values recited above.

An example of a two-sided wall panel 440 according to variousembodiments of the present invention is shown in FIG. 122, where fourembedded metal members 444 and 446 are used. Concrete is poured,finished and set to form concrete layers 469 and 470 that encasesexposed ends 452, 456, 458, and 460 of the embedded metal members.

Alternatively, as shown in FIG. 125, a two-sided wall panel 439 includesvariations of two-sided wall panel 440. In two-sided wall panel 439 one(or alternatively both, which is not shown) of exposed ends 452 and 456(and alternatively also 458 and 460) are available as attachment pointsfor a finish surface 475 such as wood, rigid plastics, wood paneling,concrete panels, cement panels, drywall, sheetrock, particle board,rigid plastic panels, or any other suitable material having decoratingand/or structural functions or other construction substrates. Theattachment is typically accomplished through the use of screws. However,other suitable fastener arrangements may be employed. In thisembodiment, the space 476 defined by the finished surface, the exposedends 444 and 446 and the expanded polymer body 442 can be used to runutilities, insulation and anchors for interior finishes as describedabove.

In this alternative embodiment, reinforcement mesh 471 is attached toexposed ends 458 and 460 of embedded metal members 444 and 446.Reinforcement mesh 471 can be made of any suitable material,non-limiting examples being fiberglass, metals such as steel, stainlesssteel and aluminum, plastics, synthetic fibers and combinations thereof.Desirably, after reinforcement mesh 471 is attached to exposed ends 458and 460, concrete layer 470 is poured, finished and set so as to encasereinforcement mesh 471 and exposed ends 458 and 460. In this embodiment,reinforcement mesh 471 increases the strength of concrete layer 470 aswell as increasing the strength of the attachment of concrete layer 470to reinforced body 441.

In another embodiment of the invention, two-sided wall panel 440 isassembled on a flat surface and a first end is lifted while a second endremains stationary resulting in orienting two-sided wall panel 440generally perpendicular to the flat surface. This is often referred toas “tilting a wall” in the art and in this embodiment of the invention,two-sided wall panel 440 is referred to as a “tilt-up wall.”

In embodiments of the tilt-up walls described herein, the exposed endsof the embedded metal members can act as a chair for the properplacement of reinforcing wire mesh and/or rebar or other reinforcingrods to the center of a concrete layer, poured, finished and set toencase the exposed ends.

As used herein, the term “concrete” refers to a hard strong buildingmaterial made by mixing a cementitous mixture with sufficient water tocause the cementitous mixture to set and bind the entire mass as isknown in the art.

In an embodiment of the invention, the concrete can be a so called“light weight concrete” in which light weight aggregate is included withthe cementitous mixture. Exemplary light weight concrete compositionsthat can be used in the present invention are disclosed in U.S. Pat.Nos. 3,021,291, 3,214,393, 3,257,338, 3,272,765, 5,622,556, 5,725,652,5,580,378, and 6,851,235, JP 9 071 449, WO 98 02 397, WO 00/61519, andWO 01/66485 the relevant portions of which are incorporated herein byreference.

In an embodiment of the invention, when the exposed ends of theone-sided wall panel and the two sided wall panel are encased inconcrete as described above, utility holes 346 and 446 act as siteswhere the set and hardened concrete fuses through the holes and therebyholds and attaches to the embedded metal members. Additionally,reinforcing rods can be placed through utility holes 346 and 446connecting embedded metal members, thus further strengthening the formedwall panel.

The wall units, floor units, tilt up insulated panels and I-beam panelsdescribed herein contain variations that are not meant as limitations.Any of the variations discussed in one embodiment can be used in anotherembodiment without limitation.

In an embodiment of the invention, a lath can be attached to the exposedends of the metal studs, metal joists or metal members of the wallunits, floor units, and expanded polymer panels; i.e. constructionelements, of the invention. The lath is capable of supporting a coveringlayer constituted by a suitable construction material. The lath caninclude one or more portions extending flush on opposite lateral sidesof the construction element, which can be embedded in and anchored alsoto the concrete used for incorporating and/or joining together one ormore adjacent construction elements.

The lath can support one or more covering layers and is typically astretched metallic lath including a rhomb-shaped mesh having alength-to-height rhomb ratio of about 2:1. The rhomb length can varybetween 0.79 and 2.36 in (20 and 60 mm), while the rhomb width can varybetween 0.39 and 1.18 in (10 and 30 mm). The stretched metallic lath canhave a thickness of from 0.0157 and 0.0591 in (0.4 and 1.5 mm) and, insome cases of from 0.0157 and 0.0394 in (0.4 and 1.0 mm). However, otherconfigurations and sizes may be employed.

The covering layers can, for example, include one or more coating layersof plaster, stucco, cement, etc. as it is or, optionally, reinforcedwith fibers of a suitable material.

A particular advantage of the construction panels, wall units, floorunits, and expanded polymer panels according to various embodiments ofthe present invention is directed to fire protection and safety. Asdescribed above, a portion of the reinforcing members in the form ofembedded framing studs are exposed and can include a web of holes formedalong their length. By exposing a section of the web of holes in theembedded framing studs, air flow is encouraged and in a fire situation,cooling of the web section of the embedded framing studs takes place.This can be very important to prolonging the failure time of a loadedwall section. Typically, in a fire test, an insulated metal stud willfail before a non-insulated stud in the center web area.

Locating spacer bars, as described above, in the exposed web section,the embedded framing studs act as a heat sink, helping to dissipate heatfrom the center web section of the embedded framing studs as well asadding to the structural properties of the wall.

The melting properties of the polymer matrix in a fire situation furtherfacilitates the cooling of the embedded framing studs web section bymelting away from the web as the temperature exceeds 200° F. (93.33°C.), allowing further air circulation and cooling of the web.

The bottom track of the wall panel, as described above, can be designedto act as a drip and containment pan in a fire event. The bottom trackarea is designed to contain the solids that melt when the polymer matrixburns. The bottom track is adapted to hold a volume at least equivalentto the volume of the expanded polymer matrix in the expanded polymerbody in liquid or molten form. Each track section can be designed tohave a holding capacity of from at least 0.2 ft³ (5.66 L), in someinstances at least 0.25 ft³ (7.08 L), in some cases at least 0.3 ft³(8.5 L) and in other cases at least 0.4 ft³ (11.33 L) and the holdingcapacity can be up to 0.75 ft³ (21.24 L), in some cases up to 0.65 ft³(18.41 L) and in other cases up to 0.1 ft³ (2.83 L) of liquid or moltenmaterial. The containment volume in the bottom track can be any value orrange between any of the values recited above. The holding capacity ofthe bottom track is typically designed to contain the solids containedin a typical 48″×96″ (1.22 m×2.44 in) construction panel.

In larger construction panels, for example those of greater height, theexterior portion of the bottom track can be slotted, allowing for theevacuation of melt materials to the exterior of the building. Thisdesign greatly diminishes the interior fire spread and improves thesafety of the interior environment of the structure during initial firespread and rescue operations.

The wall units, floor units, and expanded polymer panels of the presentinvention can be made using batch shape molding techniques. However,this approach can lead to inconsistencies and can be very time intensiveand expensive.

In an embodiment of the invention, the wall units, floor units, andexpanded polymer panels of the present invention can be made using anapparatus for molding a semi-continuous or continuous foamed plasticelement that includes

-   -   a) a mold including:        -   i) a bottom wall, a pair of opposite side walls and a cover,            and        -   ii) a molding seat, having a shape mating that of the            element, defined in the mold between the side walls, the            bottom wall and the cover;    -   b) means for displacing the cover and the side walls of the mold        towards and away from the bottom wall to longitudinally close        and respectively open the mold; and    -   c) first means for positioning in an adjustable manner said        cover away from and towards said bottom wall of the mold to        control in an adjustable and substantially continuous manner the        height of the molding seat.

The apparatus is configured to include reinforcing members which maycomprise, for example, embedded framing studs, metal bars, embeddedmetal joists and other metal profiles which may be configured asdiscussed above. As a non-limiting example, the methods and apparatusdisclosed in U.S. Pat. No. 5,792,481 can be adapted to make the wallunits, floor units, and expanded polymer panels of the presentinvention. The relevant parts of U.S. Pat. No. 5,792,481 areincorporated herein by reference.

In an embodiment of the invention, the reinforcing members 220 can bemolded into the wall units, floor units, and expanded polymer panelshaving a formed embedded end 222 and a straight exposed end 224 as shownin FIG. 127. Subsequently, the straight exposed end can be formed,worked and/or modified to provide a shaped end 228A as shown in shapedmember 226A in FIG. 128 or a shaped end 228B as shown in shaped member226B FIG. 129. Embedded ends 226A and 226B can remain unchanged fromembedded end 222. Equipment and machinery for subsequently bending,working, forming or modifying the exposed end are well known in the art.

In an embodiment of the invention, the inner surface, bottom surface, orinner face of the wall units, floor units, and expanded polymer panelsdescribed above can have a grooved surface, either molded in or appliedmechanically, to improve air flow through the annular space between theexpanded plastic and any materials attached to the exposed ends of themetal studs, metal joists or metal members of the wall units, floorunits and expanded polymer panels described above.

One aspect of various embodiments of the present invention is directedto a method of constructing a building in a first embodiment including:

-   -   providing a foundation having a series of walls having top        surfaces;    -   positioning and securing any of the floor units or systems        described above, such that the floor unit spans at least some of        the top surfaces of the foundation walls to the walls;    -   positioning and securing any of the wall systems described above        to the floor unit or system; and    -   positioning and securing a roof system as described above to a        top surface of the wall system.

Another aspect of various embodiments of the present invention providesa method of constructing a building that includes:

-   -   providing a foundation having a series of foundation walls        having top surfaces;    -   positioning and securing the composite building panels described        above, adapted for use as a floor unit, to at least some of the        top surfaces of the foundation walls;    -   positioning and securing two or more of the composite building        panels described above, adapted for use as a wall unit, to at        least part of a top surface of the floor unit, wherein a bottom        track and a top slip track are attached to a bottom end and a        top end respectively of the composite building panels; and    -   positioning and securing the composite building panels described        above, adapted for use as a roof unit, to at least some of the        top slip track of the wall units.

Still another aspect of various embodiments of the present invention isdirected to a method of constructing a multi-story building that furtherincludes:

-   -   positioning and securing the composite building panels described        above, adapted for use as a second floor unit, to at least some        of the top slip track of the wall units; and    -   positioning and securing two or more of the composite building        panels described above, adapted for use as a second wall unit,        to at least part of a top surface of the second floor unit,        wherein a bottom track and a top slip track are attached to a        bottom end and a top end respectively of the composite building        panels;    -   where the roof unit is secured to at least some of the top slip        track of the second wall units.

Thus, various forms of the present invention also provide a buildingthat contains one or more of the floor units, wall systems and roofsystems described above.

The wall units, floor units and expanded polymer panels of the presentinvention provide a number of advantages. For example, they caneliminate the need for house wrap. The expanded polymers used in thepresent invention may also have at least an equivalent rating asrequired by local building codes for house wraps.

Also, no insulation subcontractors may be required during constructionas the wall units, floor units and expanded polymer panels of theinvention already include adequate insulation. The materials ofconstruction may also effectively block low frequency sound wavesresulting from exterior noise.

The acoustical properties of the construction panels, wall units, floorunits and expanded polymer panels are particularly advantageous.Typically, metal studded structures have major acoustical or soundtransmission problems. The metal studs will generally amplify soundthrough their ability to vibrate. When the metal studs are encapsulatedin the polymer matrix, vibration is reduced, which results in reducedvibration and desirable acoustical and sound transmission properties. Anon-limiting example of a suitable test method for determining acousticsound insulative properties of various panels according to the presentinvention is ASTM E 413-04.

The panels of the present invention can have good fire resistanceproperties. Fire resistance of various wall assemblies according to thepresent invention may be evaluated according to ASTM E 119-00a.

Also, various panel embodiments of the present invention can have goodstrength and resistance to shear forces, such as wind resistance. Shearstiffness, shear strength and ductility of various wall assembliesaccording to the present invention can be evaluated according to ASTM E2126-05. Horizontal and vertical transverse load, horizontalconcentrated/point load and vertical compressive/axial load for variouswall or floor assemblies of the present invention can be evaluatedaccording to ASTM E 72-05.

The wind load resistance at the joint between two panel assemblies ofvarious embodiments of the present invention (foam adhesion strength atthe wall panel joint) can be determined according to the followingmethod. The nominal size of each test panel is 4 ft wide by 8 ft longand consists of EPS foam with 2 embedded steel studs at 2 ft on center.

Suitable testing equipment is shown in FIGS. 131-135. Two wooden panelsupports, each with the 3⅝″ track and ½″ dia. bolts at 16″ on centers,are arranged as shown in FIGS. 131-135.

Marked concrete slabs with known weights are used to simulate uniformlydistributed load on the foam. The approximate size of each slab is 1 ftby 1 ft by 3.5″ thick at 110 lb/ft³, a total weight of 32 lb/slab. A ¾″thick plywood panel, 1 ft wide by 7 ft long is used to support the slabson top of the test panels, as discussed below. Pieces of 2×4 lumber areused for bracing as shown in FIGS. 131-135. A rotary laser is used forleveling.

Data on Applied Loads versus Foam deflection is determined for twotesting scenarios. The two testing scenarios are scenario #1 in whichthe test panels have the foam side oriented as the top surface andscenario #2 in which the test panels have the steel stud side withoutfoam oriented on the top.

The testing apparatus in assembled as shown in FIGS. 131-135. Two 4 ft×8ft panels are placed inside the track side by side such that both panelshave the foam side oriented on the top and the steel stud side withoutthe foam facing downward. Weigh the 1 ft wide×7 ft long×¾″ thick plywoodpanel and place it longitudinally over the length of the test panels, 6″off each panel edge. Using a rotary laser, establish the horizontal linefor taking the measurements. Measure the distance between the horizontalto the top of plywood surface at the mid-span and note it as reading 1(or the baseline measurement), for unloaded wall panel joint. Place theknown weights/slabs of approx. 32 lb/ft starting with two slabs (64 lbtotal) at the center on the plywood panel and move towards the edges ofthe panel at increment of two slabs/reading time. Record the exact totalweight placed on the plywood and its mid-span deflection. Provide someroom at mid-span panel joint for taking foam deflection measurements.Keep adding a load increment of 64 lb; measure the distance between thesteel cable to the top of plywood and the total weight on the plywoodpanel. Repeat step #6 and 7 until foam failure. The estimated maximumload range is 250 lb to 560 lb. Record the total weight and thecorresponding foam deflection for each load change.

Repeat the above steps for testing scenario #2 (FIG. 135) namely, havingboth wall panels oriented with steel studs without foam on top and thefoam with embedded studs facing downward. The loads will be placed onthe ¾″ plywood on foam at the panel joint.

The ultimate strength of the panel joint is determined by foamseparation or failure. In order to prevent the wall finishes (i.e.plaster) from cracking or spalling, the wall panel deflection is limitedto L/240, where L is the height of the wall panel or the length of thepanel in the orientation of the test. For example, when the wall panelheight is 8 ft or 96 inches, the wall panel deflection is the heightdivided by 240, i.e., 8 ft×12 in/240 or 0.4 in.

Another potential advantage of various embodiments of the presentinvention is that less framing is required on a job site because of theprefabricated nature of the present wall units, floor units and expandedpolymer panels.

The generally faster construction time resulting from using the presentwall units, floor units and expanded polymer panels allows for earlierenclosure and protection from the elements leading to less water damageduring construction. Additionally, the provided holes, openings,conduits, chases and spaces in the present wall units, floor units andexpanded polymer panels results in faster wiring and plumbing and lessjob site scrap.

The present invention also relates to a method of doing business thatallows an architectural design layout to be accessed by the apparatusfor molding a semi-continuous or continuous foamed plastic element inorder to customize the size, shape and dimensions of the variouselements of the construction panels, wall units, floor units, andexpanded polymer panels of the invention. The architectural designlayout can be provided via software from a disk or via an Internetconnection. For those customers with Internet capabilities, access tothe present method is convenient and provides an efficient and timesaving method to design and manufacture building and/or housing units.

In a non-limiting exemplary embodiment, a customer selects anarchitectural design for a building. The architectural design includesthe unique features of each composite building panel to be used in thebuilding. The architectural design is loaded into a processing unit thattranslates the design into instructions for the apparatus for molding asemi-continuous or continuous foamed plastic element. The instructionsdirect the apparatus to continuously or semi-continuously mold panels asdescribed above and what customizing features to include in each panel.

The architectural design can include, as non-limiting examples thedimensions of and the location of openings and holes required in eachreinforcing embedded bar as well as any indentations in each compositebuilding panel needed to build the building; the dimensions of eachcomposite building panel to include thickness, width, height, spacingbetween the reinforcing members in the form of, for example, embeddedframing studs, dimensions and shape for each embedded framing studs, anychannels that need to be cut into or formed in the central body of eachcomposite building panel, any of the design features described above,any other unique features for each composite building panel, as well asgable ends accommodating any roof pitch or slope, bay window floor cutsand other design specified architectural features.

The processing unit can be any computer or device capable of readinginstructions and translating them into instructions for the apparatusfor molding a semi-continuous or continuous foamed plastic element.

The customizing features can include any of the architectural designfeatures described above. As a non-limiting example, the customizingfeatures can include forming a straight exposed end as shown in FIG. 127to a shaped end as shown in either of FIGS. 128 and 129.

In another embodiment of the invention, an interactive computer programcan be used to provide the architectural designs described above. In anembodiment of the invention, the architectural design can be inputtedusing a series of computer screen menus, where a user selects choicesmade available on a computer screen. When the design button is selected,a screen appears for additional choices for modifying the central body,the embedded framing studs, and/or the spatial relationship between thetwo. Selecting any of the menus directs to another screen where specificarchitectural design features as described above can be inputted as wellas the number of panels required that have those features. Uponselection, additional customized panels can be inputted. The user thenverifies the order by selecting an “order panels” button. Theinstructions are then relayed to the apparatus for molding asemi-continuous or continuous foamed plastic element and each of therequested number of panels having each of the architectural designfeatures are molded and cut to the order specifications. In anembodiment of the invention, all panels are automatically labeled andmarked for placement in their proper position.

In a further embodiment, the customer requests access to an interactiveprogram that steps the customer through the design process. Once thedesign is complete, the customer can save the design for future use. Thecustomer may also choose to submit the design for an order.

The use of a design program on an Internet site benefits themanufacturer in a variety of ways including a method of gatheringcustomer profiles that can later be used for mailings, etc. In addition,an Internet site that includes this unique method of doing businessreaches worldwide and generates name recognition for the manufacturer,particularly where the construction panel manufacturer is the is theonly manufacturer to offer an accessible and convenient method ofdesigning and ordering composite construction panels.

Various embodiments of the design program of the present inventionprovide an advantage for the user in his or her own business in that itraises the level of professionalism of the user by allowing prompt andon-the-spot service for his or her own customers. For example, acustomer may bring a sketch or layout for an architectural design acomposite construction panel shop requesting construction panels to usein the layout or design. In response, the panel shop owner, i.e., user,can utilize the design program to build a series of compositeconstruction panels on a computer screen with the customer by his side,and explain to the customer the benefits of the custom compositeconstruction panels. This process provides a first rate service to thecustomer, eliminates guessing, increases interaction between the panelshop and the end customer, and enhances business reputation in thefield.

FIG. 130 illustrates a method of doing business 400 between a compositeconstruction panel manufacturer 420 and a customer 414, 416 requiringthe manufacture of custom composite construction panels. A compositeconstruction panel design program is provided to a customer 414, 416 viaa hard copy 418, e.g., a disk containing a copy of the program, or viaelectronic access, e.g., the Internet or e-mail. The compositeconstruction panel design software is utilized by a customer on thecustomer's personal computer 414, 416. The customer designs one or morecomposite construction panels and delivers the completed design to themanufacturer 420. The design can be printed to provide a hard copy 418to the manufacturer 420. In a particular embodiment of the presentinvention, the finished design is uploaded to a central computer 406located at the manufacturer 420. In another particular embodiment,compatibility between the design program software and the software ofthe apparatus for molding a semi-continuous or continuous foamed plasticelement 408 allows the finished design specifications to be entered intothe apparatus 408 directly through a connection to the central computer.In another embodiment, the design specifications are entered manually byan apparatus operator. The design software stores and sorts the databased on particular panel design types, and identifies the mostefficient sequence for making panels. Thus, the software is usable as amanagement tool to simplify the work of the apparatus operator,including specifying what order to make the panels and how to maneuverparts of the apparatus to change from one panel design to the next. Themethod of doing business as illustrated in FIG. 130 reduces the time andcost to design and manufacture custom construction panels.

Various embodiments of the invention will now be described by thefollowing examples. The examples are intended to be illustrative onlyand are not intended to limit the scope of the invention.

EXAMPLE Thermal Resistance

The thermal resistance or R-value for wall assemblies that includevarious wall panels according to the present invention was determinedusing three-dimensional computer modeling simulation. Each determinationwas based upon a simulated section of wall assembly 24 inches (61 cm)wide and 12 inches (30.5 cm) high. Each simulated wall assemblyconsisted of an outer layer of 0.50 inch (1.27 cm) thick OSB board infacing engagement with a foam section of a wall panel according tovarious embodiments of the present invention in which the stud waspositioned in the center of the wall assembly area, as shown in FIGS.136-140. The foam used in the computer modeling simulation wasconventional rigid cellular polystyrene whose thermal insulationproperty met type 1 classification as per ASTM C578-04a. The simulatedassembly also included an outer layer of 0.50 inch (1.27 cm) thickgypsum board positioned in facing engagement with the exposed, oppositeend of the stud.

The thermal conductivity values for each of the wall assembly materialsused for calculations in the computer thermal modeling simulation is setforth in Table 1 below. The average thermal conductivity of the aboveexpanded polymer matrix or foam material was determined according toASTM C-518-98 (Tmean=75° F. (25° C.) and temperature difference betweentest plates ΔT=40° F. (7° C.)) of a 12″×12″×1.5″ (30.5 cm×30.5 cm×3.8cm) using two samples of foam. Twenty (20) gauge steel was used forsimulations of all steel profiles.

TABLE 1 Thermal Conductivity Wall Material (Btu-in/hr · ft² · ° F.)Steel 3.18e³ OSB Board 0.80 Gypsum board 1.11 Foam 0.28

The above thermal conductivity values were used to calculate theoreticalthermal resistance or R-value for each of five simulated wall assembliesA-E.

Referring now to FIG. 136, simulated Wall Assembly A included a wallpanel according to the present invention having a C-shaped stud asdiscussed above with reference to FIGS. 5 and 13. Simulated WallAssembly A consisted of the above-described foam 1900 having a thicknessof 3.375 inches (8.6 cm), a C-shaped stud 1902 embedded such that theouter side of the flange 1904 of the first end 1906 of the stud 1902 wasone inch (2.5 cm) from the top surface 1908 of the foam 1900 and gypsumboard 1910 in facing engagement with the outer side 1912 of the flange1914 of the second end 1916 of the stud 1902.

Referring now to FIG. 137, simulated Wall Assembly B included a wallpanel according to the present invention having a CT-shaped stud asdiscussed above with reference to FIGS. 31-34. Simulated Wall Assembly Bconsisted of the above-described foam 1918 having a thickness of 4.441inches (11.28 cm), a CT-shaped stud 1920 embedded such that the innerside 1922 of the flange 1924 of the first end 1926 of the stud 1920 wasflush with the top surface 1928 of the foam 1918 and gypsum board 1930in facing engagement with the outer side 1932 of the flange 1934 of thesecond end 1936 of the stud 1920.

Referring now to FIG. 138, simulated Wall Assembly C included a wallpanel according to the present invention having a CT-shaped stud asdiscussed above with reference to FIGS. 31-34. Simulated Wall Assembly Cconsisted of the above-described foam 1938 having a thickness of 4.375inches (11.11 cm), a CT-shaped stud 1940 embedded such that the innerside 1942 of the flange 1944 of the first end 1946 of the stud 1940 was0.25 inch (0.635 cm) above the top surface 1948 of the foam 1938 andgypsum board 1950 in facing engagement with the outer side 1952 of theflange 1954 of the second end 1956 of the stud 1940.

Referring now to FIG. 139, simulated Wall Assembly D included a wallpanel according to the present invention having a CC-shaped stud asdiscussed above with reference to FIGS. 35, 39 and 40. Simulated WallAssembly D consisted of the above-described foam 1958 having a thicknessof 4.375 inches (11.11 cm), a CC-shaped stud 1960 embedded such that theouter side 1962 of the flange 1964 of the first end 1966 of the stud1960 was flush with the top surface 1968 of the foam 1958 and gypsumboard 1970 in facing engagement with the outer side 1972 of the flange1974 of the second end 1976 of the stud 1960.

Referring now to FIG. 140, simulated Wall Assembly E included a wallpanel according to the present invention having a CC-shaped stud asdiscussed above with reference to FIGS. 35 and 51-53. Simulated WallAssembly D consisted of the above-described foam 1978 having a thicknessof 4.375 inches (11.11 cm), a CC-shaped stud 1980 embedded such that theouter side 1982 of the flange 1984 of the first end 1986 of the stud1980 was flush with the top surface 1988 of the foam 1978 and gypsumboard 1990 in facing engagement with the outer side 1992 of the flange1994 of the second end 1996 of the stud 1980.

Thermal modeling of the wall area directly surrounding the wall stud wasperformed on the above simulated wall assemblies using HEATING 7.3, athree-dimensional finite difference computer code by Oak Ridge NationalLaboratories. The computer modeling enabled analysis of theoreticaltemperature distribution in the analyzed wall systems and calculation oflocal heat fluxes, which were utilized to calculate face-to-faceR-values for the above wall assembly configurations. The results of thecomputer modeling are presented in Table 2 below.

TABLE 2 Simulated R-value Wall Assembly (ft² · ° F. · Hr/Btu) A 11.97 B13.3 C 13.56 D 14.01 E 13.97

As shown in Table 2, Wall Assemblies D and E had higher simulatedR-values compared to Wall Assemblies A-C.

Using the above simulated R-values, the framing effect on each ofsimulated Wall Assemblies A-E was determined. As used herein, “framingeffect” means the reduction of the nominal wall R-value caused byapplication of steel structural components, and is described by thefollowing formula:

f _(e)=1−R _(eff) /R _(nom)

where: f_(e) is framing effect;

R_(eff) is effective simulated R-value of the wall assembly; and

R_(nom) is nominal “in-series” R-value of cavity insulation andsheathing materials.

The results of the calculations of framing effect based upon the abovesimulated R-values are presented in Table 3 below.

TABLE 3 R-value of Framing Wall Assembly foam R_(nom) R_(eff) Effect (%)A 12.15 13.22 11.97 9.5 B 15.75 16.82 13.3 20.9 C 15.75 16.82 13.56 19.4D 15.75 16.82 14.01 16.7 E 15.75 16.82 13.97 16.9

As shown in Table 3, Wall Assembly D had the highest simulated R-valueand second lowest framing effect of Wall Assemblies A and C.

Various embodiments of the present invention are directed to wall panelsthat include a molded expandable foam panel to which any combination ofwood, metal or composite material may be attached. In variousembodiments, the wall panels are pre-insulated tilt-up wall segmentsthat incorporate elements for interior wall finishes, such as lightgauge steel stud furring strips. In various embodiments, a preformedcasting bed is used to eliminate steps of the site casting and finishingof the tilt-up wall sections. The casting beds, in various embodiments,consist of a continuous expandable foam molded panel running the full orpartial wall height of the wall section to be created. Metal, wood orcomposite members may be molded into the body of the foam matrix tocreate the supporting structure of the casting bed. The supportingstructure allows for the mechanical attachment of, for example,design-specific concrete reinforcement placement members, screed guides,edge forms, window bucks, door bucks, roof and floor attachment points,etc.

In various embodiments, the casting bed combines the light weight andhigh strength of light gauge steel framing and the insulating propertiesof expandable polystyrene in a continuous or semi-continuous moldingprocess. The expandable foam portion of the bed panel fixes in place thelight gauge interior framing members and provides the desired insulationof the final building design. The engineered concrete wall sections arepoured onto the foam panel casting bed, creating an exterior finish faceup tilt wall section. The efficient face casting of concrete panelsallows for various architectural final finishes to be applied beforelifting the panel into its wall position.

In one embodiment, the use of a top cast panel lifting attachment inconjunction with the supporting properties of the molded in light gaugesteel backing and furring studs places the concrete portion of the wallassembly in compression during the lifting step in the tilt wallconstruction. This reduces the amount and size of concrete steelreinforcements required to overcome the forces applied to the concreteportion of the wall assembly during the lifting cycle.

In one embodiment, the stay in place casting bed panel configurationconsist of a body of expandable foam, or an expandable polymer matrix asdescribed herein, that is molded in, for example, a continuous orsemi-continuous process and that allows for the flush, partial or fullencapsulation of a structural or non structural member within a foampanel that is limited in length only by methods of transportation. Oneor more light gauge steel structural, or reinforcing, members may bemolded into the casting bed. The structural members may include slotsarranged in, for example, alternating rows to allow for foam fusionthrough the holes to create thermal break pathways in the members. Thestructural members may extend out of the main foam body at predeterminedintervals to allowing for the elevation of the casting bed from thebuilding floor. In one embodiment, the exposed members provide an areafor additional load carrying removable members that supplement the loadcarrying capacity of the concrete during lifting. The members provide anelectrical cavity, plumbing cavity, additional insulation area and anattachment point for interior finishing of a wall design. The foam bodyof the panel fixes in place the bottom furring studs of the wall atpredetermined locations, thus facilitating the precise placement of theconcrete reinforcements in relationship to the load carrying structureof a wall assembly. The combination of top lifting and placement ofexternal supporting members within the exposed furring stud area allowsfor the reduction of concrete reinforcement steel to supplement thelifting process by placing the concrete in compression and adding extrasupport from the back side of the slab. The foam body, when in position,provides insulation that does not require further installation steps tocreate an effective thermal barrier. In buildings with specialrequirements for additional insulation, the stud cavity area allows forplacement of various types of supplemental insulation. The surface ofthe flush to the foam exposed steel member provides a mechanicalattachment point for concrete forming, reinforcement steel and screedguides.

FIG. 141 illustrates a top perspective view of an embodiment of a wallpanel 2010 prior to addition of concrete. The panel 2010 acts as acasting bed that includes a steel portion 2012 and an insulating portion2014. As shown in the embodiment of FIG. 141, the insulating portion2014 includes ridges and valleys. However, it can be understood that theinsulating portion 2014 may be formed in any desirable shape and theinsulating portion 2014 may be constructed of materials described hereinin connection with the wall unit 10. One side of each stud 2016 isvisible in the valleys of the insulating portion 2014. The studs 2016may be of the geometry, type and composition of the studs 14, 16 and maybe constructed of, for example, light gauge steel. The studs 2016 allowfor utilities to be run in the interior of the finished wall and alsoallow for finish materials such as drywall to be attached to theinterior of the finished wall.

FIG. 142 illustrates a top perspective view of an embodiment of the wallpanel 2010 of FIG. 141 after a concrete form 2018 and concretereinforcement 2020 are added. As illustrated in FIG. 142, the concreteform 2018 is a wooden removable form that provides support during theaddition of concrete. The reinforcement 2020, as illustrated in FIG.142, is a wire mesh that provides added strength for the concrete(illustrated in FIG. 143) that is added to the wall panel 2010.

FIG. 143 illustrates a top perspective view of an embodiment of the wallpanel 2010 of FIG. 141 during the addition of concrete 2022. As can beseen in FIG. 143, the concrete 2022 has been added to partially fill theconcrete form 2018. In practice, the concrete 2022 is added tocompletely cover the insulating portion 2014 and to fill the concreteform 2018. The concrete 2022 is finished by, for example, screeding andfloating to the desired smoothness or roughness.

FIG. 144 illustrates an exterior view of an embodiment of the wall panel2010 of FIG. 141 as it is being lifted into place. As can be seen inFIG. 144, the wall panel 2010 includes attachment points 2024 that canbe used to lift the wall panel 2010 in place using, for example, a craneor other lifting device.

FIG. 145 illustrates an interior view of an embodiment of the wall panelof 2010 FIG. 141 as it is being lifted into place. As can be seen inFIG. 145, the interior of the wall panel 2010 includes temporarysupports 2026 that are used to aid in supporting the wall panel 2010when the concrete 2022 is poured.

FIG. 146 illustrates a cross-sectional view of an embodiment of the wallpanel 2010 of FIG. 141.

Various embodiments of the systems and methods described herein aredirected to foam casting bed panels that contain structural membersmolded within an expandable foam body that fixes the position of andinsulates light gauge steel members. The expandable foam core body,which fixes the structural members, contributes to the structuralintegrity of the assembly during the erection process, thus allowing areduction in the steel concrete reinforcement required to lift the panelinto position by placing the length of the concrete slab in compressionwhen lifting from the panel top as opposed to lifting from the panelface. The structural members can be of any length and orientation andare molded within the foam core using, for example, a continuous orsemi-continuous process.

The exposed portion of the structural members extending from the bottomof the foam panel and running the length of the panel are used toelevate the casting bed off the finished floor of the building and helpsupport the concrete face during lifting. The bottom exposed steelmember acts as a furring stud to allow for plumbing and electricalchases after erecting the wall panel into its final position. The bottomexposed stud is also used to apply finishing materials such as drywallor other materials to provide the finishing of the interior walls. Theopposing flush surface of the steel member is used to mechanicallyattach the concrete form, edges, screeding guides, window bucks and doorbucks. The molded foam portion of the casting bed can vary in its depthto create the proper insulation for the building design and use. Thefoam depth can also vary to provide for differing concrete pourthickness support during the casting phase of construction. The steelmembers can be varied dependent upon concrete depth and reinforcementpositioning required by the design of differing wall heights and loadingrequirements.

While the present invention has been described in conjunction with thespecific embodiments set forth above, many alternatives, modificationsand other variations thereof will be apparent to those of ordinary skillin the art. All such alternatives, modifications and variations areintended to fall within the spirit and scope of the present invention.

1. A construction panel, comprising: an insulating member having a firstsurface and a second surface; a concrete member having a surface that isin substantial contact with the first surface of the insulating member;a structural member having a first portion and a second portion, whereinthe first portion of the structural member extends into at least aportion of the insulating member and at least a portion of the concretemember, and wherein the second portion of the structural member extendsbeyond the second surface of the insulating member.